PROJECT FEASIBILITY REPORT - Environmental Clearance

M/s Scania Steels and Powers Ltd.

PROJECT FEASIBILITYREPORT

PROPOSED EXPANSION PROJECT OF THE EXISTING INTEGRATEDSTEEL PLANT OF M/S SCANIA STEELS & POWERS LTD.

At

Village: Punjipatra, Tehsil: Tamnar, District: Raigarh,Chhattisgarh.

Contents

Section Description

1.0 Executive Summary

2.0 Introduction of the Project/ Background Information

3.0 Project Description

4.0 Site Analysis

5.0 Planning Brief

6.0 Proposed Infrastructure

7.0 Rehabilitation and Resettlement (R&R) Plan

8.0 Project Schedule and Cost Estimates

9.0 Analysis of Proposal

Pre-feasibility Report

M/s. SCANIA STEELSAND POWERS LTD.

Proposed expansion project of the existing integrated steel plant of M/s ScaniaSteels & Powers Ltd. in its own premises at Village: Punjipatra, Tehsil Tamnar,

District Raigarh in Chhattisgarh.

1.0 EXECUTIVE SUMMARYM/s Scania Steels and Powers Ltd. (formerly known as Sidhi Vinayak Sponge Iron Pvt.Ltd.) was incorporated on 25th August, 1995. The company has its registered office at 22

km Stone, Gharghoda Road, Punjipatra, Raigarh 496011, Chhattisgarh and is promoted

by Sri Sanjay Gadodia (Director). The company is operating one unit at Village:

Punjipatra, Tehsil Tamnar, District Raigarh in Chhattisgarh with existing facilities of

4x100 TPD DRI Kilns. Besides, 1 x 6 T + 1 x 8 T IFs have been implemented but are not

under operation, 2x15 T Induction Furnaces have not yet been implemented and a 8

MW WHRB based Captive Power Plant is under implementation stage, for which the

environmental clearance has already been granted by MoEF&CC.

Encouraged by the anticipating better future market, the company is planning to expand

its existing integrated steel plant by installing some new units on the available land of its

existing plant premises as well as on some additional land, adjacent to its existing plant

premises.

Salient features of the proposed project are given in Table-1.0.

Table - 1.0 : Salient Features of the Proposed Project

SL.NO.

PARTICULARS DETAILS

1. Nature of the Project Proposed expansion project of the existing integrated steel plant

2. Size of the Project Proposed Units Capacity

Sponge Iron Plant (DRI) 2X350 TPD(Capacity- 2,31,000 TPA)

Steel Melting Shop (SMS) 3X20 T with 6/11 CCM(Capacity- 1,85,000 TPA)

Captive power plant 18 MW (WHRB/)+ 6 MW (AFBC)(Total: 24 MW)

Iron Ore Beneficiation Plant 1 x 2.67 MTPA(Capacity- 26,70,000 TPA)

Pelletization Plant 2X0.8 MTPA(Capacity- 16,00,000 TPA) with dualfiring system for 0.8 MTPA Each as:

1.Gasifier (50%) - 4X6000m3/hcapacity (3 in operation and 1 asstandby)

2.Pulverized Coal Injection (40%) -





1X 4 mt/hr coal injecting capacity

3.Furnace Oil Firing System (10%) -2 X 160 kg/h capacity (1 in operationand 1 as standby).

Strip Rolling Mill 1 x 400 TPD(Capacity- 1,30,000 TPA)

Gasifier– 1 x 8,000 m3/h capacity ofGasifier and Pulverizer

ERW pipe manufacturing unit 1,00,000 TPAPipe galvanizing unit Capacity- 30,000 TPATMT Bar Re-Rolling Mill 1,80,000 TPA

Gasifier - 8,000m3/h capacity ofgasifier and pulverizer

3. Category of the Project The proposed project is under Item nos. 3(a), 1(d) and 2(b)i.e., “Metallurgical industries (ferrous & nonferrous)”, “Thermal

Power Plants” and “Mineral Beneficiation” respectively, of

Category “A” of the Schedule as per EIA Notification, 2006

and its subsequent amendments and therefore, shall require

prior Environmental Clearance from the Ministry of

Environment, Forest & Climate Change (MoEF&CC), Govt. of

India.

4. Location Details

Village Punjipatra

Tehsil Tamnar

District Raigarh

State Chhattisgarh

Geographical coordinates Latitude :22° 4'5.62"N to 22° 4'29.88"N

Longitude: 83°20'42.74"E to 83°20'59.77"E

Above Mean Sea Level (AMSL) 323 meter (1059.71 Ft.)

Location Map has been shown in Figure – 1

5. Area Details

Existing Plant Area 23.4718 ha (58 acre)

Additional Area 12.34291 ha (30.5 acre)

Total 35.81468 hectare (88.5 acres)

6. Environmental Setting Details (with approximate aerial distance & direction from the nearest plant

boundary)





a. Nearest Town Raigarh is located at 20 km South from the project site.

b. Nearest City Bilaspur is located at 125 km East from the project site.

c. Nearest National / State Highway NH-200 (Raipur, Bilaspur, Sarangarh, Raigarh, Deogarh,

Talcher and Chandikhol linking National Highway) is passing

through Raigarh about 19 kms distance (aerial distance) in

south direction from the project site.

d. Nearest Railway station Bhupdeopur Railway Station, which is located at about 14.2 km

distance (aerially) in south-west direction from the project site.

The distance of Raigarh Railway station from the project site is

about 20.5 km (aerial), located at ‘SSE’ direction w.r.t. the

project site.

e. Nearest Airport The nearest Airport is Raipur Airport in Chhattisgarh known as

Swami Vivekanand International Airport, which is located at

about 250 km (aerial distance) in west direction from the

project site.

f. National Parks, Wildlife

Sanctuaries, Biosphere

Reserves, within 10 km radius

N.A.

g. Reserved Forests (RF) /

Protected Forests (PF) within 10

km radius

Urdhana RF, Taraimal RF, Kharidungari RF, Maghat RF,

Pajhar RF, Rabo RF, Lakha RF, Barakachar RF, Dungapani

RF, Punjipatra RF, Suhai RF, and Samaruma RF are existing

within 10 km radius study area around the Project site.

h. Water Bodies (within 10 km

radius)

The important river in the study area is Kelo River, which flows

at a distance of 6.3 kms in ESE direction from the project site.

This river is a main tributary of River Mahanadi, which is the

major important river in Chhattisgarh. Kurket River, which is

another important river in the study area is flowing about 7.6

kms in WNW direction from the project site. The Rabo dam,

which is situated on the way of the Kurket River is located

about 7 kms distance in west direction from the project site.

i. Seismic Zone Seismic Zone – II

7. Cost Details

Total Cost of the Project Rs. 641.00 Crores.

8. Basic Requirements for the project





Water Requirement Quantity Source

Existing : 514 KLD

Proposed: 2464 KLD

Total : 2,978 KLD

Ground Water

Power Requirement Power requirement for the existing project:15 MW

Power requirement for the proposed project: 41 MW

Total Power requirement after the expansion of the project: 56

MW

The power will be sourced from 32 MW capacity captive power

plant & balance from the state grid.

Manpower Requirement Manpower requirement for the proposed project

ParticularsConstruction

PhaseOperationPhase

Regular 25 471

Contractual 270 220

TOTAL 295 691





2.0 INTRODUCTION OF THE PROJECT/ BACKGROUNDINFORMATION

(i) Identification of project and project proponent

Project Details

M/s Scania Steels and Powers Ltd. (formerly known as Sidhi Vinayak Sponge Iron Pvt.Ltd.) was incorporated on 25th August, 1995. The company has its registered office at 22


by Sri Sanjay Gadodia (The Director). The company is operating one unit at Village:


4x100 TPD DRI Kilns. Besides, 1 x 6 T + 1 x 8 T IFs have been implemented but are not


MW WHRB based Captive Power Plant is under implementation, for which the


Encouraged by the anticipating better future market, the company is planning to expand

its existing integrated steel plant by installing some new units on the available land of its

existing plant premises as well as on some additional land, adjacent to its existing plant

premises.

The overall project scenario is presented in Table-2.0.





Table-2.0 : Overall Project ScenarioSl.No.

Unit Description Existing units Addition/NewInstallation

Proposed units Total Configuration ProductsAs per EC vide Letter No.J-11011/1267/2007-IA II(I) dated 7th August 2018

Under operation /Under

implementation / Tobe implemented

Proposed ProjectConfiguration

1. Sponge Iron PlantDRI

4X100 TPD(Capacity 1,32,000 TPA)

4X100 TPD(Capacity 1,32,000TPA) under operation

Addition 2X350 TPD(Capacity 2,31,000 TPA)

4x100TPD+2x350 TPD(Capacity 3,63,000 TPA)

Sponge Iron

2. Induction FurnaceWith CCM

1X6 T +1X8 T + 2X15 T(Capacity 1,35,000 TPA)

1X6 T + 1X8 T IFshave beenimplemented but notunder operation

2X15 T IFs to beimplemented

Addition 3X20 T with CCM 6/11

185000 TPA

1X6 T +1X8 T + 2x15+ 3X20 TPH

320000 TPA

Billet

3. Captive powerplant

8 MW (WHRB based) 8 MW (WHRB based)Under implementation

Addition 18 MW WHRB + 6 MW AFBC(Total 24 MW)

26 MW WHRB+6MW AFBCbased Total 32 MW

Electricity

4. Iron OreBeneficiation Plant

- - NewInstallation

1X2.67 MTPA(Capacity 26,70,000 TPA)

1X2.67 MTPA(Capacity 26,70,000 TPA)

Iron OreConcentrate

5. Pelletization Plant - - NewInstallation

2X0.8 MTPA (Total 16,00,000TPA). Required fuel will be265000 kcal/MT. Following arethe details of fuel firing systemfor 0.8MTPA each.

1.Gasifier (50%)- 4X6000 m3/hcapacity (3 in operation and 1as standby)2.Pulverized Coal Injection(40%)- 1X4 mt/hr coal injectingcapacity3.Furnace Oil Firing System(10%)- 2 X 160kg/h capacity (1in operation and 1 as standby).

2X0.8 MTPA (Total 16,00,000TPA). Required fuel will be265000 kcal/MT. Followingare the details of fuel firingsystem for 0.8MTPA each.

1.Gasifier (50%)-4X6000m3/hcapacity (3 in operation and 1as standby)2.Pulverized Coal Injection(40%)- 1X4 mt/hr coalinjecting capacity3.Furnace Oil Firing System(10%)- 2 X 160kg/h capacity(1 in operation and 1 as

Iron OrePellet

Produce gasto be utilizedin Pelletplant





standby).6. Strip Rolling Mill - - New

Installation0.13 MTPA of SRM(Capacity 1,30,000 TPA)with1X8,000m3/h capacity ofgasifier and pulverizer

0.13 MTPA of SRM(Capacity 1,30,000 TPA)with1X8,000m3/h capacity ofgasifier and pulverizer

Steel Sheet

Produce gasto be utilizedin SRM plant

7. TMT BarRe-Rolling Mill

- - NewInstallation

0.18 MTPA (Capacity1,80,000TPA) with1X8,000m3/h capacity ofgasifier and pulverizer

0.18 MTPA (Capacity1,80,000TPA) with1X8,000m3/h capacity ofgasifier and pulverizer

TMT BarProduce gasto be utilizedin RRM plant

8. ERW pipemanufacturing unit

- - NewInstallation

0.1 MTPA (Capacity 1,00,000TPA)

0.1 MTPA (Capacity 1,00,000TPA)

ElectricResistanceWeldedpipes

9. Pipe galvanizingunit

- - NewInstallation

1X0.03 MTPA (Capacity30,000 TPA)

1X0.03 MTPA (Capacity30,000 TPA)

GalvanizedPipe





Project Proponent

M/s Scania Steels & Power Limited (SSPL) (formerly known as Sidhi Vinayak Sponge

Iron Pvt. Ltd.) was incorporated in the year 1995, having its registered office at 22 km

Stone, Gharghoda Road, Punjipatra, Raigarh 496011, Chhattisgarh.

(ii) Brief description of nature of the project

M/s Scania Steels and Powers Ltd. (formerly known as Sidhi Vinayak Sponge Iron Pvt.Ltd.) was incorporated on 25th August, 1995. The company has its registered office at 22


by Sri Sanjay Gadodia (The Director). The company is operating one unit at Village:


4x100 TPD DRI Kilns. Besides, 1 x 6 T + 1 x 8 T IFs have been implemented but not


MW WHRB based Captive Power Plant is under implementation, for which the


Influenced by the increase in the demand of the steel made products globally, the

company has decided to expand its existing units by installing different new units as

mentioned in Table-2. A brief description of proposed project has been mentioned below:

In the overall project after expansion, the iron ores will pass through several processes

such as Beneficiation (New installation of 26,70,000 TPA capacity) and pelletization

(New installation of 16,00,000 TPA) to concentrate the iron content in the ores (>65%) &

pellet formation respectively, followed by sponge iron manufacturing in DRI unit (4X100

TPD + 2X350 TPD) which ultimately will be melted in Steel melting shop with matching

LRF & CCM (1X6T+1X8T+2X15T + 3X20T capacity). In steel melting shop, hot liquid

steel will be converted to hot Billets (3,20,000 TPA). The Billets thus formed will pass

through strip rolling mill (1,30,000 TPA capacity to manufacture steel sheet) and re-

rolling mill (1,80,000 TPA to manufacture TMT bars). A portion of the steel sheet will be

used in ERW pipe manufacturing unit (1,00,000 TPA capacity to manufacture Electric

Resistance Welded pipes). The ERW pipes will be galvanized in the proposed Pipe

galvanizing unit (30,000 TPA capacity to manufacture GI pipes). Captive power plant of

32 MW capacity will be installed, out of which 26 MW will be based on WHRB (8 MW

WHRB based CPP is under progress of implementation for which EC has already been

granted), utilizing waste heat generated from sponge iron plant and the balance 6 MW

will be based on AFBC boiler, utilizing dolochar generated from sponge iron plant.

The proposed units will be installed on the available land within the existing plant

premises of 23.4718 ha (58 acre) as well as on some additional land [12.34291 ha (30.5





acre], adjacent to the existing plant premises, thus comprising a total land area of

35.81468 hectare (88.5 acres) at Village: Punjipatra, Tehsil Tamnar, District Raigarh in

Chhattisgarh. The additional land is vacant and industrial in nature. The land is generally

flat and does not come under flood zone.

(ii) Need for the project and its importance to the Country and Region

India was the world’s 3rd largest steel producer in the year 2017. Steel industry being a

core sector, reflects the overall economic growth in the long term period. The per capita

consumption of steel is considered as an important index of the socio-economic

development including living standards of the people in any country. All major industrial

economies are influenced by the existence of a strong steel industry. The economic

growth has been largely shaped by the strength of their steel industries in their initial

stages of development.

Post de-regulation the Indian steel industry has been registering manifold development

in the context of the buoyant economy and rising demand for steel. Rapid increase in

production has made India to become the 2nd largest producer of crude steel during the

year 2018, from its 3rd largest status in 2017. The country became the largest producer

of sponge iron in the world and the 3rd largest finished steel consumer in the world after

USA and China. In a de-regulated, liberal economic scenario like India, the role of a

government is to formulate policy guidelines to facilitate the institutional

structure/mechanism for creating a favourable environment for improving efficiency as

well as performance of the steel sector. In this connection, the Government of India has

issued the National Steel Policy 2017, which focuses on long term growth for the Indian

steel industry, both on demand and supply sides by 2030-31. The Government has also

laid down a policy to encourage domestically manufactured Iron & Steel products by

providing them with preference in Government procurement. India has set a target to

achieve 300 million tonnes of annual steel production by the year 2025-30.

The growth of the steel industry significantly contributes to economic growth of the

Nation as well as to the region as it generates employment both directly and also due to

development of downstream industries. The infrastructural and other social amenities

grow in the region leading to overall development of the region.

The proposed project of M/s. Scania Steels and Powers Ltd. will cover new units and

technologies. The above will lead to manufacture steel products at a lower cost and

more importantly in a more environment friendly way.





(iv) Demand - Supply Gap

Growing economies and their fast-paced infrastructure projects are increasing the

demand in the iron and steel industry across the country. It is a product of large and

technologically complex industries having strong forward and backward linkage in terms

of material flow and income generation. Manufacturers and suppliers are prepping up to

meet the tremendous demands of iron and steel products across the country.

Current Market Scenario

SAIL, Tata Steel, JSW Steel etc. are some of the leading steel companies in India.

Indian Steel industry showed tremendous growth after the liberalization of the sector in

the 1990s. High-grade iron ore and non-coking coal, the two main ingredients for

producing steel, are easily available in India. Moreover, a robust MSME sector with labor

availability at competitive rates and a young workforce has led to the growth of steel

industry in India.

Future Growth for Iron and Steel

As per the World Steel Association insights, demand for steel will see a slow decline in

China while India along with MENA and ASEAN countries will grow. The growth of the

countries will depend on the structural reforms in the sector and the successful

implementation of government reform policies.

Globally, technological changes and regulations are affecting the steel demand. Energy

prices and substitute materials along with environmental protection policies are affecting

the global demand. At the regional level, urbanization, government reforms and

manufacturing processes are creating an impact on the iron and steel demand.

India Vision 2030

According to the Global Steel Market outlook report, the steel demand will increase from

1537 MT in 2014 to 1992 MT in 2030. Infrastructure development in developing

economies will increase the demand for iron and steel in the years to come.

Generally, market gaps in meeting the demands for steel are managed with the import of

steel. The Indian Steel Industry is expected to flourish with the National Steel Policy

2017. As per the policy, domestic manufacturing will be given more preference. The

policy charts a growth plan for the Indian Iron and Steel industry with the demand and

supply side growth by 2030-31.





Thus, the Iron and Steel industry has a raising scope for growth and development in

India and grabbing the opportunities in this industry with due consideration of the

environmental affairs will be considered as a boon to the overall economic structure of

the country.

(v) Imports vs. Indigenous production

Imports:-

As per the monthly report of Iron & Steel, February 2020, the following import export

scenario of iron and steel in India has been derived:

On Month on Month (M-o-M) basis, exports of finished steel during February, 2020

declined by 17.8% and stood at 0.570 MT. Hike in domestic prices was one of the

main factors behind export decline. Export, however, was higher than imports by

0.169 MT during the same period.

A declining trend in imports has been observed since September 2019. Barring, the

month of January 2020, imports were contained below 0.430 MT between Nov.,

2019 to Feb., 2020. On M-o-M basis, imports at 0.401 MT declined by 16% during

February 2020. The same also declined by 31.2% over CPLY.

For cumulative period, April- February, 2020, India imported 6.39 MT finished steel

products as against 7.13 MT thereby registering 10.4% decline over CPLY.

Domestic competitive prices as compared to high landed prices of imports were the

main reasons for decline. During this period steel imports were found to be declined.

Maximum decline was observed in imports from Vietnam. During February 2020,

the maximum decline was witnessed from Japan. Korea continued to be the top

exporter to India, followed by China and Japan.

Export scenario:

As per the monthly report of Iron & Steel, February 2020, the following export scenario of

iron and steel in India has been derived:

On M-o-M basis, exports of finished steel have observed a declining trend since

October 2019. Exports at 1.019 MT were maximum during September 2019, which

reduced to almost half during February 2020.

However, India remained net exporter in steel for the seven consecutive months i.e.,

August, 2019 to February, 2020. Steel exports registered a significant growth of

34.9% during April, 2019 - February, 2020 over CPLY with trade surplus at 1.39 MT.





Steel exports to Vietnam and Taiwan witnessed an increase during April- February

2020, whereas, it declined in case of Belgium, Spain and Malaysia. Vietnam

remained top most destination of Indian steel exports by accounting nearly 29% of

total steel exports. During February 2020 nearly 60% of total exports accounted by

Vietnam, UAE and Nepal with share of 28.3%, 15.8% and 14.8% respectively.

M-o-M basis, Indian iron ore exports at 2.05 MT declined by 28% during February

2020. Iron ore exports dropped due to weak demand following Corona Virus

outbreak in China, which led falling inquiries for February 2020 shipments. Indian

iron ore exports to China at 1.71 MT, dropped by 35% in February 2020.

(vi) Export Possibility

As the demand of Iron and steel products in India is very high, at present the Scope of

Export is limited. However, In future when the production capacity of iron and steel

products will increase it my become prudent to conceive the export of its products.

(vii) Domestic / Export Markets

While the demand for steel will continue to grow in traditional sectors such as

infrastructure, construction, housing automotive, steel tubes and pipes, consumer

durable, packaging, and ground transportation, specialized steel will be increasingly

used in hi-tech engineering industries such as power generation, petrochemicals,

fertilizers etc. The new airports and railway metro projects will require a large amount of

steel. Hence, the domestic and export markets for steel sector will rise.

(viii) Employment Generation (Direct and Indirect) due to the project

M/s. Scania Steels and Powers Ltd. will employ maximum human resources from local

area. Only when skilled human resources are not available locally, the same will be

brought from outside.

The proposed project will generate both direct & indirect employment. Approx. 295

persons will be provided employment during construction phase of the proposed project,

which is of temporary in nature. However, during commercial operation, about 470

person will be employed directly. Skilled and unskilled people on daily average will be

employed. The Company will give preference to the local people during construction and

operation phases of the project, depending upon the skill, job requirement and capability.

Table-3.0 gives a break-up of the manpower requirement.





Table-3.0: Manpower Requirement for the proposed project

ParticularsConstruction

PhaseOperationPhase

Regular 25 471

Contractual 270 220

TOTAL 295 691

3.0 PROJECT DESCRIPTION(i) Type of project including interlinked and interdependent projects, if any:

The project is interdependent in nature.

M/s. Scania Steels and Powers Limited proposes to expand its existing steel plant by

installing some new units on the available land of its existing plant premises as well as

on some additional land adjacent to its existing plant premises at Village: Punjipatra,

Tehsil Tamnar, District Raigarh in Chhattisgarh.

(ii) Location (map showing general location, specific location and project boundary &project site layout) with coordinates

The project site is situated at P.O & Vill.: Saraipali, Gharghora Road, Dist. Raigarh,

Chhasttisgarh. Its geo-graphical coordinates are 22°4'29.26"N & 83°20'42.72"E to 22°

4'5.79"N & 83°20'53.00"E and 22°4'12.78"N & 83°20'39.64"E to 22°4'16.58"N &

83°21'4.78"E with Above Mean Sea Level of 323 meters (1059.71 ft). Figures 1.0 showsthe location of the project site in Indian map. Figures 2a & 2b show the location of the

project site in Google Earth & Toposheet respectively and Figure 3.0 shows the plant

layout of the project.





Figure-1.0 : Location Map

Project Site: Village: Punjipatra, Tehsil Tamnar, District Raigarh in Chhattisgarh.

Geographical Co-ordinates: Latitude :22° 4'5.62"N to 22° 4'29.88"N

And Longitude: 83°20'42.74"E to 83°20'59.77"EAbove Mean Sea Level (AMSL) 323 m (1059.71 ft)





Figure-2 a: Project Site on Google Earth

Project-feasibility Report


Proposed expansion project of the existing integrated steel plant of M/s ScaniaSteels & Powers Ltd. at Village: Punjipatra, Tehsil Tamnar, District Raigarh in

Chhattisgarh.

Figure - 2 b: Project Site on Toposheet




Chhattisgarh.

DRAFT

Figure-3.0 : Proposed Plant Layout




Chhattisgarh.

DRAFT

(iii) Details of alternative sites consideration and basis of selecting the proposed site,particularly the environmental considerations gone into should be highlighted. -

The proposed units will be installed on the available land within the existing plant premises of

23.4718 ha (58 acre) as well as on some additional land [12.34291 ha (30.5 acre], adjacent to the

existing plant premises, thus comprising a total land area of 35.81468 hectare (88.5 acres) at Village:

Punjipatra, Tehsil Tamnar, District Raigarh in Chhattisgarh. The additional land is vacant and

industrial in nature. The acquisition of this additional land is under process. The land is generally

flat and does not come under flood zone.

As the proposed project is expansion of the existing steel plant, no alternative sites have been

explored.

(iv) Size or magnitude of operation

The company is planning to expand its existing steel plant by installing some new units on the

available land of its existing plant premises as well as on some additional land, adjacent to its

existing plant premises. The proposed units and their capacities are mentioned below:

(v) Project Description with Process Details

The detail manufacturing process of all the proposed units is as under:

Proposed Units Capacity

Sponge Iron Plant (DRI) 2X350 TPD(Capacity- 2,31,000 TPA)

SMS With Caster 3X20 T with 6/11 CCM(Capacity- 1,85,000 TPA)

Captive power plant 18 MW(WHRB/)+6 MW (AFBC)(Total: 24 MW)

Iron Ore Beneficiation Plant 1 x 2.67 MTPA(Capacity- 26,70,000 TPA)

Pelletization Plant 2X0.8 MTPA(Capacity- 16,00,000 TPA) with dual firing system for 0.8MTPA Each as:

1.Gasifier (50%)-4X6000 m3/h capacity (3 units will be in operation and 1 will beas standby)2.Pulverized Coal Injection (40%)- 1X4 mt/hr coal injecting capacity3.Furnace Oil Firing System (10%)- 2X160 kg/h capacity (1 in operation and 1as standby).

Strip Rolling Mill 1 x 400 TPD(Capacity- 1,30,000 TPA)with1 x 8,000 m3/h capacity of Gasifier and Pulverizer

ERW pipe manufacturingunit

1,00,000 TPA

Pipe galvanizing unit Capacity- 30,000 TPATMT Bar Re-Rolling Mill 1,80,000TPA

With 1 x 8,000m3/h capacity of gasifier and pulverizer




Chhattisgarh.

DRAFT

1. IRON ORE BENIFICATION PLANT (1X2.67 MTPA)

In order to cater beneficiated iron ore to the pellet plant, it is proposed to set up a new 1X2.67 MTPAMTPA iron ore beneficiation plant for production of 26,70,000 TPA of beneficiated iron ore fines.

Table 4 below presents the configuration of the proposed project.

Table-4.0: Configuration of Beneficiation Plant (1 x 2.67 MTPA)

Description Capacity

Nos.of Unit 1

Throughput Capacity, MTPA 2.67

No. of working days/ Year 330

No. of working hours/ day 24

Beneficiated Iron oreproduction (MTPA)

2.67

Beneficiation Plant mainly involves in grinding of iron-ore fines and separation of gangue tothe extent possible, within the required operational limits.

Beneficiation process mainly consists of:

1- Primary Grinding

2- Hydro cyclone

3- Three stage spiral classification

4- Two stage high gradient magnetic separation

5- Regrinding & thickening of concentrate received from both spirals & magneticseparators

Iron-ore fines will be brought from the mine. The fines will be stockpiled in the raw material yard.

Iron-ore fines will be reclaimed through pay-loaders and tippers and transported to silos through

shuttle conveyor. Vibrating feeders are provided below each of the silo. The output from the Vibro

feeder will feed the grinding mill feed conveyors.

Thereafter, primary grinding in wet grinding mill shall be carried out.

The mill feed conveyors will feed primary ball mill. The primary ball mill’s discharge is collected in

pump sump for pumping to hydro cyclone clusters. The overflow from the cyclone is sent to slime

thickener. The cyclone under flow is fed to a bank of rougher spirals. The concentrate from the

rougher spirals will be processed in Scavenger & cleaner spirals. The tailings from the rougher &

cleaner spirals are fed to intermediate slime thickener. The concentrates from cleaner spiral are




Chhattisgarh.

DRAFT

pumped to secondary hydro cyclone. The under flow from cyclone is fed to regrinding mills for

further grinding to required product size. The overflow from the cyclone is fed to concentrate

thickener.

The under flow from the concentrate thickener is pumped to slurry storage tanks. The thickened

concentrate at approximately 65-66% solids by weight will be pumped into the pellet plant by single

stage pumping to the slurry storage tank fitted with agitation mechanism.

The under size from the screens is fed to High Gradient Magnetic Separator (HGMS) for recovery of

concentrate from slimes. The concentrate from HGMS is further ground in the same regrinding mill,

which is close circulated with secondary hydro cyclone. The concentrate over flow from hydro

cyclone is thickened in concentrate thickener before pumping to slurry storage tanks provided with

agitators. The tailing from HGMS is fed to a tailing thickener. The tailing thickener underflow is

pumped to a tailing dam in the beneficiation plant site. The overflow from the tailing thickener is sent

to process water tank for re-circulation in the process. Significant quantity of water of tailing dam

shall be lost in evaporation.

The slurry from this storage tank is fed to pressure filters to obtain filter cakes. When wet grinding

process is adopted, the preparation of flux materials and binders (if Bentonite is used) is done in dry

state and separate grinding equipment is to be installed.

The composition of the IO beneficiation plant is as follows:

Fe Content: 62 – 63%

Al2O3: 1.5 – 2%

SiO2: 2.5 – 3.5%

FIG-4: Schematic diagram of the iron ore beneficiation process




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2. PELLETIZATION PLANTM/s SSPL proposes to install a 2X0.8 MTPA pelletization plant to produce 16,00,000 TPA of pellet. The

pelletization plant will be fueled by-

1. Gasifier (50%)- 4X6000 m3/h capacity (3 in operation and 1 as standby)

2. Pulverized Coal Injection (40%)- 1X4 mt/hr coal injecting capacity.

3. Furnace Oil Firing System (10%)- 2 X 160 kg/h capacity (1 in operation and 1 as standby).

The proposed pellet plant is designed to produce iron oxide pellets suitable for use in DRI and Blast

Furnace.

Process Description

The pellet plant will produce oxide pellets suitable for use in DRI kiln. Pellets are heat hardened

balls produced from concentrates and natural iron ores of different mineralogical and chemical

composition. The pellets have improved properties for iron making. Pelletization process involves

feed preparation, green ball formation, pellet Induration and product dispatch.

Iron Ore Pellet Plant

In order to make entire technological level, environment protection level, advanced stage and

suitable for operation and maintenance, it is designed to have some new material, new technology,

new process, new equipment and new structure, with aim at improving reliability, reducing

investment, extending life campaign, lowering operation cost, facilitating maintenance and

replacement.

Travel grate machine - Rotary kiln process features as:

A. Drying, Preheating, Baking, Cooling etc. are carried on different equipment including travel gratemachine, rotary kiln and annular machine, leading to uniform quality of product and reliable andsimplified equipment.

B. Each set of equipment can be controlled individually and adjusted conveniently, which is stronglyadapted for raw material, particularly hematite.

C. Good adaptability for fuel. Low fuel consumption, power consumption and low operation cost.Rotary kiln is step-less adjusted by speed reducer and AC frequency converter to enable operationsmooth and stabilized.

To adopt advanced air flow system, fully recovering sensible heat of high temperature flue gasgenerated from annular cooler, making utilization of thermal energy to the maximum extent andlowering thermal consumption of pellet.

Main operation processes are centralized controlled and adjusted by computer, main technologicalprocesses are monitored and administrated by industrious TV with high automatic control level.




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High attention is put on the protection of environment, which purify the dust contained waste gas byuse of high effective dust catcher to discharge into the air after reaching standard discharge norm.

Dust is collected in centralized manner, which can be fully recovered and utilized.

FIG-5: Process Flow Diagram of Pellet Plant

The Iron Ore Pelletization Plant has the following major units:

Iron Ore grinding system & Filtration

The fine grinding machine feeding fines of incoming raw iron ore is around 63.5%. Granular sizes ofoutput of iron ore after grinding is around 70 to 90 passing through 325 mesh, subject to filtration toproduce iron ore concentrate with water content of around 9% to 10%. Preliminary iron ore grinding iscarried out in closed circuit ball mill and Wet screen.

Proportioning Room

Proportioning Room is complete with bunkers for different feed materials. The Iron ore filter cake istransferred from grinding unit through belt conveyor into the high level of proportioning room. Dustcollected from multi cyclone dust catchers and ESP is fed into the proportioning dust bunkers throughchannel pneumatically by air. Bentonite, dust & LCD bunkers are installed with discharge holes foreach.

Mixing room




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Iron ore fines, Bentonite, flux, coke and ESP dust are all mixed uniformly in a mixer. As per watercontent of material, some certain quantities of water are added so as to maintain watercontent beforeballing process ranged from 9 to 10%.

Balling Room

Mixed material is transferred through belt conveyor into the high level of balling room, where thematerial mix is discharged through plough-type dumper above belt conveyor separately into mixedmaterial bunker, under which, balling discs are installed. Green ball produced from balling disc istransferred from collective belt conveyor into the green ball distribution system in the travel gratemachine for material distribution.

Green ball distribution system

Green ball from balling room is fed into the distribution system through belt conveyor. In reciprocatingprocess, head swinging belt conveyor feed the green ball into large ball roll screen for screening.Unqualified green ball of more than 16 mm is separated out and then fed back into the balling roomthrough return material system. Green ball of less than 16mm is fed onto wide belt conveyor, whichtransfers the green ball onto roll distributor through AC frequency converter. Roll distributor fedqualified green ball of 5-16 mm onto travel grate machine. Undersized balls less than 5 mm arerecycled to the balling system.

Baking System

Travel grate machine, rotary kiln and annular circular machine are designed to formulate bakingsystem. Green balls are dried and preheated in the travel grate machine, and then baked, solidified inthe rotary kiln, cooled in the annular cooler.

/06/2021Travel Grate Machine

Effective length of travel grate machine is 36 meters. Length of wind box is 3 meters. Thetravel grate machine is divided into 4 zones, which are separately for suction drying zone,preheating zone I and preheating zone II.

Drying zone, I & II

In suction drying zone, recoverable hot waste gas suctioned by heat resistant fans from windboxes in preheating zone II penetrates material layer downward from up, to keep green ballfree of water and dried.

A set of main suction blower is provided to exhaust waste gas from wind box into the airthrough ESP.

Preheating Zone, I:

Hot waste gas flow in the preheating zone I is utilized to keep drying green ball throughmaterial layer, in order to assure pellet to sustain high temperature in Preheating Zone II. Hot




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waste gas in preheating zone I is merged through main pipes at a side of wind box with hotwaste gas from suction drying zone to be discharged into air all together through ESP, Mainsuction blowers and chimney.

Preheating Zone, II

In preheating zone II, pellet is further heated. Pellet is partially solidified and hardened toachieve certain strength to sustain impact caused by pellet falling from travel grate machineinto the rotary kiln to avoid being crushed in process of rotation of the kiln.

Rotary Kiln

The size of the kiln is Φ4.3 Mtr. X 32 Mtr. Pellet, after preheated by the traveling gratemachine, is discharged into the end of the kiln through scrapper and chute. The kiln isprovided with HFO & producer gas spraying gun in its head. The well baked pellet, isdischarged, after large sizes of pellet is sieved out by fixed screen at the head of the rotarykiln, into the material receiving hopper of annular cooler.

Annular Cooler

Effective area of annular cooler is 55 SqM. The annular cooler consists of Rotary mechanism,Wind Box, Driving Device, Frame, Upper Cover and etc. The pellet, after cooled down tobelow 100 centigrade in the annular cooler, is discharged outside through discharginghopper.




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04/06/Main air suction blowers

Waste gas from preheating zone I merge with those from Wind Box of Suction drying zone isdischarged through ESP and main chimney into the air. Dust content of waste gas to bedischarged into the air is not more than 40mg/Nm3.

Finished Product

Cooled pellet, after discharged from material discharging hopper of annular cooler, istransferred through belt conveyor into the Junction Box, where the cooled pellet 100 to 150deg C is transferred through metal belt conveyor into the finished product transportationsystem. Then pellet is withdrawn by the reclaimer when necessary, and they are loaded bytruck and transported outside.

Coal Gasifier for the Pelletizing Plant

Coal gasification process is one of the cleanest technologies currently available. In theprocess of coal gasification, water gas is produced with zero fugitive emission. The coalgasification process stands better in comparison to other fuels and there is about 50%reduction in the air emissions. From environmental point view, the usage producer gasthrough Coal Gasifier has proven lowest NOx, SOx, particulate matter and lower hazardousair pollutants. Ash is in the form of small clinkers /granules and also be slightly wet whendisposed. Therefore, it does not fly and being used for brick making. Water used in theprocess is either converted into steam or re-circulated; therefore, there is no waste waterstream.

In view of better efficiency of heat in kilns and clean coal technology, the company hasadopted dual firing system utilizing producer gas and heavy furnace oil in the ratio of70:30% in both the Pelletizing Plants.

Process Description: The Coal Gasification Facility consists of:

1. Coal conveying from ground hopper to top of battery of coal Gasifiers2. Coal Gasifiers3. Hot gas clean-up system consisting of gravity settlers & cyclones4. Insulated gas piping5. Process water system6. Ash handling consisting of ash conveyor and storage hopper7. Instrumentation, automation & control for the entire facility.

The process of gasification primarily consists of partial oxidation of coal to produce producergas. The gasification reactions are carried out in a cylindrical vessel, called a gasifier/pulverized base. The gasifier main reactor is double walled /water jacketed. Water in waterjacket is converted into steam. The mixture of atmospheric air and steam from water jacketreacts with coal in the gasifier reactor to generate producer gas. The gas comes out of thegasifier main reactor at 350oC – 450oC and then passes through gravity settler and cyclonefor removal of course dust particles. The gas from individual Gasifiers travels to common gasduct and then to the kiln. The gas is conveyed to kiln in “hot” condition. So, the ‘tar in vaporform’ & ‘fine carbon particles’ are carried along with gas to the kiln through insulated pipeline




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and burn in the kiln.

Air blowers provided with each of the gasifier supply atmospheric air into the Gasifiers. Thesteam from water jacketed double wall mixes with air and enters the gasifier main reactor. Airinlet water seal prevents air from leakage. The excess steam is vented into the atmosphere.

Coal conveyor, coming from the coal handling plant, feeds coal into the coal bunkersprovided on top of each of the gasifier. From the coal bunker, coal enters the gasifier mainreactor through a coal feeding mechanism. The coal feeding mechanism has a double doorarrangement to enable feeding of coal into the reactor while it is in operation.

Ash is discharged from ash pans of individual gasifier on to the ash conveyor, which runsalongside the ash pans of all the Gasifiers. Ash conveyor carries the ash on to the ash heap,from where it is transported for disposal. Ash is in the form of small clinkers / granules andalso be slightly wet when disposed. Therefore, it does not fly. This ash is used for brickmaking.

De-mineralized water (DM water) is used in the water jacket of gasifier main reactor forconversion into steam. DM water is first stored in a common ground tank and then pumped toindividual overhead tanks for further use. Gas generated in the gasifier main reactor isbranched into 2 streams. One stream goes to flare and the other to the main line. Flare lineis used during gasifier start-up only, when the gas does not contain any combustibleconstituents. During start-up, the gas coming out at flare mainly contains CO2& N2. Assoonas the gas lights up at the flare, it is diverted to the main line. Flare water seal isolatesthe flare line from the rest of the system while the Gasifiers are in normal operation.

Gas, traveling to main line, passes through gravity settler, cyclone separator and water sealisolator, into the common gas duct. Gravity settler and cyclone separator separate coarsedust particles from gas while the fine particles are carried to kiln along with gas. Water sealisolator is used for isolating individual Gasifiers from the common duct. Water seals havebeen provided at various locations. Water used in various water seals is re-circulated andreused.

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0Fuel Firing System

In view of better efficiency of heat in kilns and clean coal technology, the company is adoptingapulverized Coal firing system along with furnace oil in the Pelletizing Plant in addition of coalgas.

There is 1No. of Coal gasifiers of 8000 Nm3/hr, in the 8 lac TPA Pellet Plant in first phase.There is proposal to utilize Coal mix in the Gasification Plant in place of oil.

Source of Major Raw Material

Iron ore fines: Iron ore fines are purchased from the iron ore belt of Joda-Barbil region. Coke/Coal Fines: From IOCL, Paradeep (Imported Coke/Coal). Dolomite: Dolomite is sourced from Bilaspur state of Chhattisgarh and

Sundergarh district of Odisha. 4-Bentonite: Bentonite is from local traders of Bhuj, Gujarat product.

3. SPONGE IRON PLANT (DRI)M/s Scania Steels and Powers Ltd. is proposing to install 2X350 TPD DRI kilns in addition

to its existing 4X100 TPD DRI Kilns for the overall sponge iron production to the tune of

3,63,000 TPA, which will be used as raw material in Induction Furnaces.

Manufacturing ProcessThe proposed project shall use the coal based process in which iron oxide in pellet / iron ore

will be reduced with non coking coal in a rotary kiln to make sponge iron. The raw materials

(Pellet / iron ore, coal and dolomite), in desired quantities and sizes, are fed into the rotary kiln

from the feed end, after the rotary kiln has been fired and reaches the desired temperature.

The rotary kiln is a refractory lined cylindrical vessel on which blowers and air pipes are

mounted to provide combustion air to the kiln. The rotary kiln has a downward slope and is

mounted on rollers to enable rotation. The angle of inclination, rotational speed, and length of

time the charge is exposed to the atmosphere and temperature has important bearings on the

quality of the end product. The rotary kiln has three functions as: It is a heat exchanger,

Vessel for chemical reaction, Conveyor for solids.

With the rotation of the kiln, the charge moves down the slope and the surface of the material

is exposed to heat. The heat exchange takes place via the non-refractory lining of the kiln.

The reduction from oxide to metal occurs by gradual removal of oxygen at various

temperatures giving rise to various intermediate oxides. Hot sponge iron is discharged from

the kiln discharge end and taken into the rotary cooler. The effluent gas that contains coal

volatile matter, fine carbon particles, iron fines and sponge iron dust is treated separately in

the waste gas handling system. The system consists of:

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a) Dust settling chamber

b) After burner chamber

c) Waste heat recovery boiler

d) Electrostatic precipitator

e) ID fan

f) Chimney

Direct Reduced Iron / Sponge Iron Process (DRI)The process of reduction takes place inside the rotary kiln, which is mounted on tyres and

supported by support rollers. The transverse motion of the kiln is controlled with the help of

hydro thruster and thrust rollers. The kiln is rotated at the rate of 0.35 rpm with the help of a

girth gear mounted on the kiln and connected with pinion drives, which in turn are coupled

with gear boxes and motors.

The direct reduction of iron oxides inside the kiln is held due to CO gas, which is generated

out of coal at nearly 950°C. Shell air fans are mounted on the kiln, which inject air in

controlled manner into the kiln for creating reducing atmosphere. The CO reacts with Fe2O3

and reduces it to Fe. The kiln is lined with refractory for sustaining the high temperature.

The hot sponge iron is then cooled by indirect cooling inside a cooler. The rotary cooler is

supported on tyres and support rollers. The cooler is rotated at the rate of 0.6 rpm with the

help of a girth gear mounted on the cooler and connected with single pinion drive, which is

coupled with a gearbox and motor. The water is sprayed on the cooler shell while the sponge

iron travels inside the cooler and hence, the material gets cooled at outlet to 150°C while

discharged on the product conveyor.

In the kiln, the iron oxide will be heated to the reduction temperature of 1000-1050°C. The iron

oxide of the ore will be reduced to metallic iron by carbon dioxide generated in the kiln from

coal. The heat required for the reduction process will also be supplied by the combustion of

coal.

Thermocouple will be installed along the length of the kiln shell for measurement of thermal

profile of the kiln. The temperature will be controlled by regulating the amount of combustion

air admitted into the kiln through no. of ports with help of fans mounted on the kiln will have

variable speed drive. Auxiliary drive is provided for slow rotation.

The cooler will be lined with refractory castable for about 4.0 m from the feed end. Bypass

arrangement will be provided at discharge end of the cooler for emergency discharge of

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materials. The cooled product will be conveyed to the product processing building by a

system of belt conveyors.

The cooling water will be collected in the trough below the cooler and sent to the cooling

tower for cooling. The cooled water will be re-circulated. Closed circuit cooling system will be

followed in the plant.

Product SeparationThe sponge iron along with unburnt coal in the form of dolochar comes out of the cooler. The

sponge iron being magnetic is separated out of the dolochar by passing it through a magnetic

separator. The sponge iron and char, recovered separately, are stored in the storage bunkers

and discharged through trucks.

Off gas cleaning systemThe off gases moving in counter current of material flow inside the kiln are at a temperature of

1000°C and carry coal dust, which is passed through dust settling chamber and after burning

chamber (ABC). Air is added into the ABC for converting CO to CO2. The hot flue gas stream

is taken to the waste heat recovery boiler (WHRB) for utilization of the sensible heat for

making steam. The off gases are then allowed to pass through ESP for removal of dust so

that the concentration of dust is limited to below 30 mg/Nm3 before being discharged from the

chimney.

In-plant de-dusting systemReverse air bag filter shall be installed for catching the dust from various conveyors, material

handling equipment and-product handling equipment. The dust collected from the bag filter

shall be conveyed pneumatically to a distant location and discharged on trucks in wet

condition.

Raw Materials required for Sponge Iron manufactureThe main raw materials for sponge iron production are pellet / iron ore, coal, and dolomite.

Preferred Raw Material CharacteristicsThe principal raw material will be used for production of steel making grade DRI in the sponge

making process is pellet / iron ore, non-coking coal and dolomite.

The pellet/iron ore should be preferably high in Fe content (>62% Fe). Coal with a high

reactivity and high fusion temperature is preferred. The coal should also be non-coking.

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A low ash fusion temperature is undesirable as it promotes formation of accretions in the kiln.

The coal ash composition is also important as a siliceous ash might react with ferrous oxide to

form low melting ferrous silicate and interfere with the reduction to metallic iron.

Product characteristics of Sponge Iron are presented in Table-4.0.

Table-4.0 : Sponge Iron (coal based) characteristics

Fe (total) 92% min

Fe (met) 83 % max

Metallization 90 % max

Carbon 0.25 % max

S 0.025% max

P 0.06% max

Re-oxidation Non-pyrophoric characteristics

Major plant facilitiesThe major plant facilities for the sponge iron plant envisaged are as follows:

1. Day bins

2. Rotary kiln and cooler

3. Off gas system including waste heat power generation

4. Product processing and storage.

Day binsThere shall be a day bin building to cater to raw material requirement of the kiln. These bins will

generally have storage of about one day’s requirement of pellet, feed coal (4-8, 8-18 mm) &

dolomite (1-4 mm). Weigh feeders will be provided to draw the required quantity of various

materials in proportion from the bins and the same will be conveyed to the kiln feed and

discharge end.

Rotary kiln and coolerThe rotary kilns with 5 m of diameter, 125 m length will be provided for reduction of iron oxides

into sponge iron using non-coking coal as reductant. The kiln will be lined with abrasion resistant

refractory castables throughout its length with damps at feed end and discharge end.

The rotary kiln will be supported on four piers. A slope of about 2.5% shall be maintained. Then

main drive of the kiln will be by A.C motors with VVF drive control. The speed of the kiln will be

in the range of 0.3-0.9 & 1.05-3.15 rpm. The auxiliary drive of the kiln will be by A.C motors.

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The other main components of the kiln will be as given below:

a. Feed end and discharge end transition housing of welded steel construction with

refractory lining including feed chute.

b. Pneumatic cylinder actuated labyrinth air seal complete with auto lubricating at feed

end and discharge end.

c. On board equipment like fans, manifolds, ports, slip ring, instrumentation etc.

d. Cooling fans at feed end and discharge end.

e. Feed end double pendulum valve & dust valves.

Product processing and storageThere shall be one product processing unit for handling the cooler discharge. The product

containing sponge iron, char and spent lime from the cooler discharge end will be discharged to

a set of conveyors and sent to the product processing building. The kiln cooler system shall

have a separate surge bin. Product from surge bin can be withdrawn through vibrating feeder

and to the product will first be screened in a double deck screen having 3 mm and 20 mm

screens. +20 materials shall be dumped as rejects. The screened product i.e. +3 – 20 mm and -

3 mm fraction shall separately be sent to the product storage separation. Sponge iron lump (3 –

20) shall be sent to the product storage building for storing in two no. of bunkers where three

days storage has been proposed. The sponge ion fines (-3 mm) will be stored in the fines

bunker in the product processing building itself where one day storage will be provided. The

sponge iron lump and fines will be further conveyed from the respective bunkers by truck to the

steel making unit as per the requirement. The char/non-magnetic shall be stored in a separate

bin from where it will be sent to the power plant through conveyors for its utilization for power

generation in FBC boiler. Indicative process flow diagram of DRI Plant is presented below in

Figure 6.0.

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Figure-6.0 : Process flow diagram of DRI plant

4. STEEL MELTING SHOP

The company has proposed to install 3X20T of IFs in addition to its existing 1X6T + 1X8T IFs

(Implemented but not under operation) and 2 x15T (not yet installed) with matching LRF & CCM

for the overall production of 320000 TPA of billets.

The plant will produce steel in the form of billets, Steel Sheet, Electric Resistance Welded pipes

through IF-CCM-RM route. Steel making will be done using induction furnaces. A brief

description of the process is dealt in subsequent paragraphs and the process flow sheet is given

below in Figure 7.0.

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Figure-7.0 : Process flow diagram of SMS unit with CCM

Steel Making by Induction FurnaceThe greatest advantage of the Induction Furnace is its low capital cost compared with other

types of Melting Units. Its installation is relatively easier and its operation simpler. Among other

advantages, there is very little heat loss from the furnace as the bath is constantly covered and

there is practically no loss during its operation. The molten metal in an Induction Furnace is

circulated automatically by electromagnetic action so that when alloy additions are made, a

homogeneous product is ensured in minimum time. The time between tap and charge, the

charging time, power delays etc. are items of utmost importance is meeting the objective of

maximum output in tones/hours at a low operational cost. The disadvantage of the induction

furnace is that the melting process requires usually selected scrap because major refining is not

possible.

The process for manufacturing steel may be broadly divided into the following stages:

i. Melting the charge mixed of steel & Iron scrap

ii. Ladle teeming practice for Casting (OR)

iii. Direct teeming practice for billet Casting unladdable teeming machine

The furnace is switched on, current starts flowing at a high rate and a comparatively low voltage

through the induction coils of the furnace, producing an induced magnetic field inside the central

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space of the coils where the crucible is located. The induced magnetic fluxes thus generated out

through the packed charge in the crucible, which is placed centrally inside the induction coil.

As the magnetic fluxes generated out through the scraps and complete the circuit, they generate

and induce eddy current in the scrap. This induced eddy current, as it flows through the highly

resistive bath of scrap, generates tremendous heat and melting starts. It is thus apparent that

the melting rate depends primarily on two things (1) the density of magnetic fluxes and (2)

compactness of the charge. The charge mixed arrangement has already been described. The

magnetic fluxes can be controlled by varying input of power to the furnace, especially the current

and frequency.

In a medium frequency furnace, the frequency range normally varies between 150-10K cycles /

second. This heat is developed mainly in the outer rim of the metal in the charge but is carried

quickly to the center by conduction. Soon a pool of molten metal forms in the bottom causing the

charging to sink. At this point any remaining charge mixed is added gradually. The eddy current,

which is generated in the charge, has other uses. It imparts a molten effect on the liquid steel,

which is thereby stirred and mixed and heated more homogeneously. This stirring effect is

inversely proportional to the frequency of the furnace and so that furnace frequency is selected

in accordance with the purpose for which the furnace will be utilized.

The melting continues till all the charge is melted and the bath develops a convex surface.

However, as the convex surface is not favorable to slag treatment, the power input is then

naturally decreased to flatten the convexity and to reduce the circulation rate when refining

under a reducing slag. The reduced flow of the liquid metal accelerates the purification reactions

by constantly bringing new metal into close contact with the slag. Before the actual reduction of

steel is done, the liquid steel which might contain some trapped oxygen is first treated with some

suitable deoxidizer. When no purification is attempted, the chief metallurgical advantages of the

process attributable to the stirring action are uniformity of the product, control over the super

heat temperature and the opportunity afforded by the conditions of the melt to control de-

oxidation through proper addition.

As soon as the charge has melted clear and de-oxidising ions have ceased, any objectionable

slag is skimmed off, and the necessary alloying elements are added. When these additives have

melted and diffused through the bath of the power input may be increased to bring the

temperature of metal up to the point most desirable for pouring. The current is then turned off

and the furnace is tilted for pouring into a ladle. As soon as pouring has ceased, any slag

adhering to the wall of the crucible is crapped out and the furnace is readied for charging again.

As the furnace is equipped with a higher cover over the crucible very little oxidation occurs

during melting. Such a cover also serves to prevent cooling by radiation from the surface heat

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loss and protecting the metal is unnecessary, though slags are used in special cases. Another

advantage of the induction furnace is that there is hardly any melting loss compared with the arc

furnace.

A metal Recovery Plant is proposed to recover the metals from the stag, to be generated.

Continuous casting machine 6/11The molten steel from the IF is cast in a continuous casting machine to produce billets. In some

processes, the cast shape is torch cut to length and transported hot to the hot rolling mill for

further processing. Other steel mills have reheat furnaces. Steel billets are allowed to cool, and

then be reheated in a furnace prior to rolling the billets into bars or other shapes.

The process is continuous because liquid steel is continuously poured into a ‘bottomless’ mould

at the same rate as a continuous steel casting is extracted.

Before casting begins a dummy bar is used to close the bottom of the mould.

A ladle of molten steel is lifted above the casting machine and a hole in the

bottom of the ladle is opened, allowing the liquid steel to pour into the mould to

form the required shape.

As the steel’s outer surface solidifies in the mould, the dummy bar is slowly

withdrawn through the machine, pulling the steel with it.

Water sprays along the machine to cool/ solidify the steel.

At the end of the machine, the steel is cut to the required length by on line PLC

based hot shearing machine.

After cut, hot billets will directly go to rolling mill through conveyer.

5. Rolling Mill

M/s Scania Steels and Powers Ltd. has proposed to install two types of rolling mills viz., Strip

Rolling Mill and TMT Bar re-rolling mill with individual preheating systems as standby

arrangement. However, the pre-heating system will not be required during normal plant

operation when there will be hot billet charging to the rolling mills. A brief description of both the

types of rolling mills has been described below:

STRIP MILL (STRIP/SHEET/COIL)

Semi-finished product from the CCM of IF will be converted into finished products such as strip,

sheet, coil, wire, bar and wire rope (Capacity 1,30,000 TPA).

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Manufacturing process of Conventional Rolling Mill:

I. Ingot/ Billet after proper sizing through Gas Cutting or billet Shearing Machine willbe pushed in reheating furnace. The reheating furnace will be fired by F.O./ Coalbased producer gas plant. There will be high energy efficiency heat recuperatorsinstalled in with it.

II. Then pushed out to rolling stands for re-rolling. Steel Pieces are rolled through allstands in order to get required shape of finished goods i.e., MS Strips and otherRerolled products. It is proposed to produce MS Strips at present; however, infuture the Mills may be used to produce Wire Rod or other Rerolled products also.

III. After Cooling rerolled products are shifted to finished yard, after inspection, areready for dispatch to tube mill/stock yard.

Rolling Mill for TMT bars

The company proposes to install a re-rolling mill of 1,80,000 TPA capacity. The fuel for the

reheating furnace will be producer gas, which will be produced in the proposed producer gas

plant.

TMT BarsTMT or Thermo Mechanically Treated bars are high-strength reinforcement bars having a

hardened outer core and a soft inner core. They are manufactured under a process called

Thermo Mechanical Treatment, after which they are named.

Steel – an alloy of iron, carbon, and other elements – is a major component used in buildings,

infrastructure, tools, ships, automobiles, machines etc., because of its high tensile strength.

However, steel structures are adversely affected by corrosion, fire and other environmental and

accidental factors, thus severely compromising their structural integrity, safety, and longevity.

Thus, steel is subjected to various processes to increase its mechanical properties like ductility,

hardness, corrosion resistance, and yield strength. Thermo Mechanical Treatment (TMT) is one

of these many processes; it combines mechanical or plastic deformation processes like

compression or forging, rolling etc. with thermal processes like heat-treatment, water quenching,

and heating and cooling at various rates into a single process.

The steps included in Thermo Mechanical Treatment Process are as follows:

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Heating, rolling, and forming of reinforced bar: The Hot steel billets from CCM at

approximately 1200°C to 1250°C and then rolled to reshape the billets into the final size and

shape of reinforced bar (rebar) by passing the billets through a rolling mill stand.

Quenching: When the hot reinforced bar leaves the final rolling mill stand, it is instantaneously

quenched – a type of heat treatment where the rebars are rapidly cooled by water in a

quenching box to obtain certain material properties. Quenching prevents the occurrence of

undesired processes such as phase transformations. It accomplishes this by reducing the time

frame during which these undesired reactions have a higher chance of occurring. Also, the

sudden drastic change in temperature toughens the outer layer of the steel bar, thus enhancing

its tensile strength and durability. This is because quenching converts the outer surface of the

reinforced bar to Martensite, a hard form of steel and causes it to shrink, which in turn

pressurizes the core, thus helping to form the correct crystal structures. As a result of this

process, the surface of the quenched bar becomes cold and hardened, while the core still

remains hot.

Self-tempering: After leaving the quenching box, a temperature gradient is formed through the

cross-section of the quenched bar. As a result, heat flows from the core, as it is at a relatively

higher temperature to the outer surface. This causes the correct tempering of the outer

martensitic layer into a structure called Tempered Martensite and the formation of an

intermediate ring of Martensite and Bainite (a plate-like microstructure). The core still stays in

the austenitic (a typical cubical crystalline structure, commonly called as gamma-phase iron)

state at this stage.

Atmospheric Cooling: After the self-tempering process, the bars are subjected to atmospheric

cooling to equalize the temperature difference between the soft inner core and the hardened

exterior. Once the bars are completely cooled down, the austenitic core gets transformed into a

ductile ferrite-pearlite structure.

Therefore, the cross-section of the final product demonstrates a variation in its crystal

microstructure having a tough, strong, tempered martensite in its outermost layer, an

intermediate layer of Martensite and Bainite, and a refined, tough and ductile ferrite and pearlite

core.

On the other hand, lower grades of rebar are twisted when cold to harden them in order to

increase their strength. However, TMT bars do not need hardening explicitly as the quenching

process accomplishes this. Since TMT does not involve any twisting, no torsional stress occurs,

which does remove the chances of surface defects forming in TMT bars. Hence, TMT bars are

less susceptible to corrosion as opposed to cold, twisted, and deformed (CTD) bars.

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The production quality of TMT bar depends on three major factors:

Quality of raw materials.

A properly designed and automated rolling mill stand.

A well-designed quenching and tempering technology.

TMT bars, having a uniform and concentrated hardened periphery and a considerably softer

core, will have the desired tensile strength coupled with high elongation as required in the

construction of buildings located in areas with regular seismic activity.

6. Producer gas plantProducer gas is the cheapest fuel and can substitute Furnace Oil, LDO, Kerosene, other fuel

and other gases. It is ideally adopted to industrial heating operation, because of its uniformity &

cleanliness. The company proposes to install producer gas plant the details of which is furnished

below:

1.Gasifier- 4X6000m3/h capacity (3 in operation and one as standby) for pellet plant.

2 nos. 8,000 Nm3/h capacity producer gas plant along with 2 nos. coal pulverizers, one for the

proposed Strip Rolling Mill & another for the proposed Re-Rolling Mill.

Producer gas is generated by injecting a blast of air and steam through a layer of incandescent

coal or coke. The carbon of the coal or cock combines with oxygen of the air to from carbon

dioxide and the carbon dioxide as it goes up meets hot unburnt coal or cock in reduction zone to

form carbon monoxide. The water vapors which passes through the fuel reacts to form carbon

monoxide and hydrogen.

The chief combustible elements in producer Gas are carbon monoxide and some hydrocarbon.

Gasification is a major & unique element in the development of advance, improved, Renewable

energy system. It is a thermo-chemical process that converts solid biomass coal/ bio-coal to a

low heat value (LHV) gaseous fuel "Producer Gas". This Producer Gas is fuel for many different

application of thermal power in the equipment like Furnaces, Kilns dryers, rolling mills and heat

treatment equipment. Boiler, Hot air Generator.

The equipment to be utilized for gasification is known as a Gasifier. On the basis of flow of gas

in the reactor, gasifier is generally divided into two major groups like UPDRAFT and Downdraft

Gasfire. An updraft Gasifire is more efficent & generally utilized for Thermal application. Figure8.0 (a & b) show the schematic diagrams of Updraught & Downdraught Gasifiers.

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Figure-8.0 :a. Updraught or counter current gasifierb. Downdraught or co-current gasifier

Producer gas is formed in the cylindrical vessel. The diameter of this cylindrical vessel is around

3 m and the height is around 4 m. The coal and coke are added from the upper zone known as

the pre-heated zone with the help of a cup and cone. The lowest zone of these vessels is known

as the ash zone. The inlet is attached from this ash zone. This inlet carries the oxygen gas and

steam gas to the upper zone (oxidation zone) also known as the combustion zone. The coal is

heated in the presence of these oxygen gas and steam gas. In the oxidation zone, the carbon

reacts with oxygen and forms the carbon dioxide and carbon monoxide gas as a product of

combustion. The third zone is known as the reduction zone. In this reduction zone, the steam

reacts with the carbon and produces carbon monoxide gas and hydrogen gas as a product of

combustion. In the pyrolysis zone, the produced gas passed through this zone and heated at

even higher temperature and released out from the outlet.

The Reaction Involved in the Formation of Producer Gas

Oxidation Reaction: This reaction takes place in the oxidation zone. This reaction is exothermic.

2C + O₂→ CO₂ C + O₂→ 2CO

Reduction Reaction: This reaction occurs in the reduction zone. This reaction is endothermic.

C + H₂O → CO + H₂ CO₂ + C → 2CO

Feature & Advantages produced gas

The Bio-mass Gasifire system is capable of gasifying several types of solid fuel such asCharcoal, Lignite, Imported Steam coal, Briquettes and high efficiency cock.

a b

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Low Nox formation due to low flame temperature.

Extermely Low particulates and smoke emission due to the complete direct firing ofProducer

Gas compare to solid fules / liquid fules firing

Worldwide accepted environment friendly Renewable technology.

Chemical Composition of Producer Gas (Approx)

The chemical composition of producer gas is as follows:

Carbon dioxide : 3%

Hydrogen gas : 10- 15 %

Carbon monoxide : 22 - 30 %

Nitrogen gas : 50 - 55 %

Methane : 6%

Waste management in Produced Gas Plant

Ash generated during the gasification process travels down into the ash pan placed below the

reactor. The ash pan is slowly rotated to facilitate discharge of ash from pan onto the ash

conveyor. Ash pan also contains water, into which the bottom of the reactor is dipped. This

creates a rotating water seal joint for discharge of ash through the water seal. The ash conveyor

carries ash from each of the gasifiers to the ash dump (ash bunker). From the ash dump (ash

bunker), the ash will be periodically removed and used in cement plant and brick manufacturing.

Gas coming out of individual gasifier reactors will be hot and raw. The gas cooling & cleaning

system consists of indirect cooling type centrifugal tar separators and electrostatic precipitators.

Hot-raw gas, exiting from the gasifiers will first be cooled and about 80% tar is separated in

centrifugal tar separators. Gas from these separators goes to a common header to be conveyed

to electrostatic tar separators. Tar from centrifugal tar separators gets collected in individual

collection pots and then is pumped to tar storage. Cooling water is continuously circulated to tar

separators for external cooling of gas. The temperature of cooling water is maintained within

limits with the help of cooling towers.

Residual tar in gas is separated out in electrostatic tar precipitators. The tar, so separated, will

be first collected in tar pits and then transferred to tar tanks for storage. Tar has a good market

value and will be sold to authorized vendor.

Various water seals are used for isolation of gas within the gasifier block, along the gas pipeline

and in the gas utilization area. Water used in the seals will be collected when the seals are

emptied and the same water is re-used for filling the seals. So, there is no regular disposal of

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seal water. But there could be occasional disposal of seal-water. Such water (which would

contain traces of phenols) would be incinerated in the after burning chambers of sponge iron

kilns.

Coal Tar generated from PGP shall be collected using “Centrifugal Tar Separator” and will be

used as Fuel in DRI Kiln / alternately sold to authorize re-processors. No waste water will be

generated from the process.

CENTRIFUGAL TAR SEPARATOR

Indirect Type Centrifugal Tar Separator’ consists of 2 stages of indirect cooling of gas and

simultaneous centrifugal tar separation. As can be seen in the figure, gas rises upwards from the

water seal into the first stage of separator. At the top of first stage, high velocity centrifugal

motion is imparted to gas to separate out droplets of tar. As the gas travels down in the outer

annular path, it is cooled by external forced cooling. At the same time, condensed and separated

tar travels down along the wall of the annular path. As the gas enters the second stage, it is

cooled and therefore tar separation is more effective. Here, again, similar action of high velocity

centrifugal separation and indirect forced cooling is repeated.

PHENOLIC WATER, TAR & TAR SLUDGE RECOVERY SYSTEM

Phenolic wastewater generated during the stage of gas cooling shall be charged in the ABC of

DRI plant and will also be used for making green ball for using it in pellet kiln. Over flow water,

spillage water will be connected to underground tank, where the tar will be settled. Soft water

plant will be installed so as pH is maintained. Plant will be designed for Zero discharge and

spillage water will be used for spraying on coal and coke if necessitated.

7. ERW PIPE MANUFACTURING UNIT

The company has planned to set up a new ERW pipe manufacturing unit for the production of

1,00,000 TPA of ERW pipe. In Electric Resistance Welding (ERW) process, pipe is

manufactured by cold-forming a flat sheet of steel into a cylindrical shape. Then current is

passed between the two edges of the steel cylinder to heat the steel to a point at which the

edges are forced together to form a bond without the use of welding filler material. Several

Electric Resistance Welding (ERW) processes are available for pipe production. The two main

types of ERW are:

(i) High Frequency Welding

(ii) Rotary Contact Wheel Welding.

(i) High Frequency Welding

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Initially ERW manufacturing process used low frequency A.C. current to heat the edges. This

low frequency process was used from the 1920’s until 1970. In 1970, the low frequency process

was superseded by a high frequency ERW process which produced a higher quality weld. Over

time, the welds of low frequency ERW pipe was found to be susceptible to selective seam

corrosion, hook cracks, and inadequate bonding of the seams, so low frequency ERW is no

longer used to manufacture pipe. The high frequency ERW process is still being used in pipe

manufacturing.

There are two types of High Frequency ERW processes.

(a) High Frequency Induction Welding

(b) High Frequency Contact Welding

(a) In High Frequency Induction Welding, the weld current is transmitted to the material through

a work coil in front of the weld point. The work coil does not contact the pipe. The electrical

current is induced into the pipe material through magnetic fields that surround the pipe. High

frequency induction welding eliminates contact marks and reduces the setup required when

changing pipe size.

(b) In High Frequency Contact Welding, the weld current is transmitted to the material through

contacts that ride on the strip. The weld power is applied directly to the pipe, which makes this

process more electrically efficient than high frequency induction welding. Because it is more

efficient, it is well-suited to large diameter and high wall thickness pipe production.

Both the High Frequency Induction Welding and High Frequency Contact Welding processes

have been presented in Figure-9.0.

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Figure-9.0: High Frequency Induction Welding and High Frequency ContactWelding processes

(ii) Rotary contact welding

In Rotary Contact Wheel Welding (Figure-10.0), the electrical current is transmitted through a

contact wheel at the weld point. The contact wheel also applies some of the forge pressure

necessary for the welding process. The three main types of rotary contact wheel welders are AC,

DC, and square wave. In all three power supplies, electrical current is transferred by brush

assemblies that engage slip rings attached to a rotating shaft that supports the contact wheels.

These contact wheels transfer the current to the strip edges.

Rotary contact welding is useful for applications that cannot accommodate an impeder inside the

pipe or tube. Examples of this are small-diameter refrigeration grade tube and tube that is

painted on the ID immediately after the welding process.

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Figure-10.0: Rotary contact welding process

A few advantages to note with ERW pipe:

There are no fusion metals used during the manufacturing process. This means that the

pipe is extremely strong and durable.

The weld seam cannot be seen or felt. This is a major difference when looking at the

double submerged arc welding process, which creates an obvious welded bead that

might need to be eliminated.

With the advances in high-frequency electric currents for welding, the process is far

easier and safer.

The conventional ERW manufacturing procedures of steel pipes and tubes are shown in

Figure- 11.0

Figure 11.0 : Conventional electric resistance welding (ERW) manufacturing proceduresof the steel pipes and tubes.

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8. PIPE GALVANIZING UNIT

M/s Scania Steels and Powers Ltd. Proposes to install a new pipe galvanization unit of 30,000

TPA capacity. Galvanized iron pipes are widely known for a wide range of practical applications

— water transportation, in agriculture, telecommunications, plumbing, and more. Galvanized iron

pipes are great to utilize because of its corrosion resistance and its durability for both indoor and

outdoor use. The process descriptions of galvanizing pipes are as follows:

Metal Preparation

Dipping Phase into Molten Zinc

Cooling, Finishing, and Drying

Metal Preparation

The iron pipes firstly go through a meticulous surface preparation. Typically, the process of the

surface preparation of galvanized iron pipes operates as follows:

Firstly, the steel is cleansed with the use of a caustic solution — a corrosive substance in

where it will completely remove all oil, grease, dirt, and excess pain.

After the caustic solution is rinsed off, the iron pipe is then pickled. Pickling is a metal

surface treatment that is used to eliminate stains, impurities, contaminants, rust, or scale from

ferrous metals.

The iron pipe is pickled in an acidic solution to get rid of the mill scale or also known as

the flaky surface of the hot-rolled steel.

After the pickling solution is rinsed off, the iron pipe will not proceed to fluxing. Commonly,

zinc ammonium chloride is used to the base metal to suppress oxidation of the cleaned surface.

Dipping Phase into Molten Zinc

Here, the iron pipes are generously immersed in a bath of molten zinc of around 449 degrees

Celsius. Here, it will alloy a thick and robust layer on the surface of the base metal.

Cooling, Finishing, and Drying

After the zinc dipping technique is done, it is now time for the galvanized iron pipes to cool down.

Typically, the galvanized iron pipes are cooled in a quench tank for it to cool down quickly and

restrain unwanted effects of the newly formed coating with the atmosphere of its surroundings.

9. CAPTIVE POWER PLANT

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The company intends to set up a Captive Power Plant of 24 MW capacity (out of which 18 MW

will be based on WHRB and 6 MW will be AFBC boiler based) in addition to its 8 MW WHRB

based CPP (under implementation stage for which EC has already been granted). After the

implementation of the total project, the total electricity generation will be 32 MW.

The waste heat, generated from the DRI plant will be utilized in WHRBs for the production of 26

MW electricity. The dolo-char generated from the DRI plant along with coal will be utilized in the

proposed AFBC boiler for the production of 6 MW electricity.

Atmospheric Fluidized Bed Combustion (AFBC) technology has the potential to use

alternative fuel sources such as coal, wood, or waste, and is able to reduce and control nitrogen

oxide (NOx) and sulfur dioxide (SO2) emissions. In AFBC, coal is crushed to a size of 1 – 10 mm

depending on the rank of coal, type of fuel feed and fed into the combustion chamber. The

atmospheric air, which acts as both the fluidization air and combustion air, is delivered at a

pressure and flows through the bed after being preheated by the exhaust flue gases. The

velocity of fluidising air is in the range of 1.2 to 3.7 m /sec. The rate at which air is blown through

the bed determines the amount of fuel that can be reacted. Almost all AFBC/ bubbling bed

boilers use in-bed evaporator tubes in the bed of limestone, sand and fuel for extracting the heat

from the bed to maintain the bed temperature.

The bed depth is usually 0.9 m to 1.5 m deep and the pressure drop averages about 1 inch of

water per inch of bed depth. Very little material leaves the bubbling bed – only about 2 to 4 kg of

solids are recycled per ton of fuel burned. Typical fluidized bed combustors of this type is shown

in Figures 12 a.

The combustion gases pass over the super heater sections of the boiler, flow past the

economizer, the dust collectors and the air preheaters before being exhausted to atmosphere.

The main special feature of atmospheric fluidised bed combustion is the constraint imposed by

the relatively narrow temperature range within which the bed must be operated. With coal, there

is risk of clinker formation in the bed if the temperature exceeds 950oC and loss of combustion

efficiency if the temperature falls below 800oC. For efficient sulphur retention, the temperature

should be in the range of 800oC to 850oC.

AFBC boilers comprise of following systems:

a) Fuel feeding system

b) Air Distributor

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c) Bed & In-bed heat transfer surface

d) Ash handling system

e) Many of these are common to all types of FBC boilers

a) Fuel Feeding system For feeding fuel, sorbents like limestone or dolomite, usually two

methods are followed:

Under Bed Pneumatic FeedingIf the fuel is coal, it is crushed to 1-6 mm size and pneumatically transported from feed hopper to

the combustor through a feed pipe piercing the distributor. Based on the capacity of the boiler,

the number of feed points is increased, as it is necessary to distribute the fuel into the bed

uniformly.

Over-Bed FeedingThe crushed coal, 6-10 mm size is conveyed from coal bunker to a spreader by a screw

conveyor. The spreader distributes the coal over the surface of the bed uniformly. This type of

fuel feeding system accepts over size fuel also and eliminates transport lines, when compared to

under-bed feeding system.

b) Air DistributorThe purpose of the distributor is to introduce the fluidizing air evenly through the bed cross

section thereby keeping the solid particles in constant motion, and preventing the formation of

defluidization zones within the bed. The distributor, which forms the furnace floor, is normally

constructed from metal plate with a number of perforations in a definite geometric pattern. The

perforations may be located in simple nozzles or nozzles with bubble caps, which serve to

prevent solid particles from flowing back into the space below the distributor.

The distributor plate is protected from high temperature of the furnace by:

i) Refractory Lining

ii) A Static Layer of the Bed Material or

iii) Water Cooled Tubes.

Bed & In-Bed Heat Transfer Surface:BedThe bed material can be sand, ash, crushed refractory or limestone, with an average size of

about 1 mm. Depending on the bed height these are of two types: shallow bed and deep bed. At

the same fluidizing velocity, the two ends fluidise differently, thus affecting the heat transfer to an

immersed heat transfer surfaces. A shallow bed offers a lower bed resistance and hence a lower

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pressure drop and lower fan power consumption. In the case of deep bed, the pressure drop is

more and this increases the effective gas velocity and also the fan power.

In-Bed Heat Transfer Surface

In a fluidized in-bed heat transfer process, it is necessary to transfer heat between the bed

material and an immersed surface, which could be that of a tube bundle, or a coil. The heat

exchanger orientation can be horizontal, vertical or inclined. From a pressure drop point of view,

a horizontal bundle in a shallow bed is more attractive than a vertical bundle in a deep bed. Also,

the heat transfer in the bed depends on number of parameters like (i) bed pressure (ii) bed

temperature (iii) superficial gas velocity (iv) particle size (v) Heat exchanger design and (vi) gas

distributor plate design.

Ash Handling SystemBottom ash removalBottom ash from proposed boiler will be carried through a submerged belt conveyor to silo. From

Silo it will be disposed to ash dump area in covered trucks in moistened condition.

Fly ash removalThe fly ash from the proposed boiler will be collected in economizer hoppers, air heater hoppers,

ESP hoppers and will be conveyed through dense phase pneumatic conveying system to silo.

The fly ash to be disposed from the silo will be moistened to reduce the dust while collecting the

ash. The system will be provided with telescopic chute and rotary feeder for loading the ash into

covered trucks.

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Figure-12 a: Schematic representation of AFBC

Brief description of major plant and equipmentThe proposed project will comprise of the following major systems:

Fluidized bed combustion boiler with auxiliaries

Steam turbine generator and auxiliaries

De-aerator and feed water system

Electrical systems

Instrumentation and controls

Compressed air system (service air and instrument air)

Handling & hoisting facilities

Plant communication system

Ventilation and air conditioning

Fire fighting detection & alarm system

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Waste Heat Recovery BoilerAfter burning chamber (ABC) and Dust settling chamber (DSC) will be located at the exit of DRI

Kilns. Part of the dust carried by the waste gases will settle down at DSC. The DSC and ABC

assembly will be connected to the DRI Plant Kiln through refractory lined duct.

The combustibles in the waste gases are burnt in the After Burning Chamber which will raise the

waste gas temperature thus making the waste gases free from carbon mono-oxide. Provision for

spraying water will be made to control the temperature if required. From ABC outlet the WHRB

will be connected through a refractory lined duct. An emergency stack cap on the top of ABC will

be provided for diverting the waste gases to atmosphere when WHRB is under shutdown or

break down. The energy balance of WHRB boiler based on DRI waste gas is as follows (Table-5.0):

Table-5.0: Energy balance of WHRB

Project ConfigurationHot Waste

GasGeneration

Ultimate Hot Waste GasGeneration

Remarks

ExistingDRI Plant

4X100 TPD

90,000 NM3/

hr. with gas

temperature

900o -

1000oC

Total 90,000 NM3/hr with gas

temperature 900o-1000oC will be

generated from the DRI Plant.

Such volume of waste gas will

generate around 34 tonnes of

steam from WHRB boiler.

34 tonnes of

steam will be

generated from

the WHRB

boilers will be

used for

generation of 8

MW Power

(Project under

implementation

stage).

ProposedDRI Plant

(2x350 TPD)

1,80,000

NM3/ hr. with

gas

temperature

900o -

1000oC

Total 1,80,000 NM3/hr with gas

temperature 900o-1000oC will be

generated from the DRI Plant.

Such volume of waste gas will

generate around 68 tonnes of

steam from WHRB boiler.

78 tonnes of

steam

generated from

WHRB boilers

will be used for

generation of 18

MW Power.

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The boiler will be complete with evaporator steam drum, mud drum, bank of super heaters,

economizer, atemperator, air fans, ESP, internal piping etc. Soot blowing and super heater

atemperation system will be also provided. Boiler will be provided with blow down tanks (IBD,

CBD etc), sample cooler.

Flue gas cleaning systemThe exhaust gases will be discharged from boiler to ESP and then into the atmosphere through

Induced Draft fan and chimney. The pressure drop in the boiler ducts and ESP will be kept to

match with the requirement of ID fan. The boiler will be of semi out door type with a weather

canopy and side covering of trapeze corrugated steel sheets or other suitable materials as

available.

The gases flue gas having huge quantity of dust particles will pass out of the WHRB through one

multi-field Electrostatic Precipitator before escaping into the atmosphere through the stack. The

ESP will be installed between the WHRB and the stack. The dust content in gas down stream of

ESP shall be limited to 30 mg/Nm3. The ESP unit will be provided with transformers, rectifier and

controls. The dust particles will be collected below ESP in the hoppers and conveyed by means

of conveyors or pneumatically and stored in silos. The collected dust will be subsequently

disposed off by trucks. Figure-12 b shows the schematic diagram of WHRB based CPP.

(vi) Raw material required along with estimated quantity, likely source, marketing areaof final products, mode of transport of raw material and finished product.The major raw material, which will be handled, consists of Iron Ore fines / Lump, Coal,

dolomite, Limestone, bentonite etc. The annual requirement of major raw materials,

which will be required for the proposed project is presented below in Table 6.0.

PROCESS FLOW DIAGRAM – WASTE HEAT RECOVERY POWER PLANT

Figure-12 b: Schematic representation of WHRB

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Table - 6.0 : Raw Material Requirement for the overall project

Sl.No

Units Rawmaterials

ExistingProject

Proposedproject

Totalrequirement

Source

1. Sponge IronPlant

Iron OrePellet

2,12,000 TPA 3,71,000 TPA 5,83,000 TPA In House

Coal 1,60,000 TPA 2,80,000 TPA 4,40,000 TPA Imported,Local Market

Dolomite 5,300 TPA 9,275 TPA 14,575 TPA Local Market

2. InductionFurnace

Sponge Iron 1,14,400 TPA 1,80,400 TPA 2,94,800 TPA In House

Pig Iron 24,000 TPA 32,725 TPA 56,725 TPA Local Market

Scrap 13,835 TPA 25,362 TPA 39,197TPA In House &Local Market

Ferro Alloys 975 TPA 1,534 TPA 2,509 TPA Local Market

3. Iron oreBeneficiationPlant

Iron ore fines - 37,40,000TPA 37,40,000 TPA Local Market

4. Pellet Plant Iron oreconcentrate

- 16,00,000 TPA 16,00,000 TPA In House

5 Gasifier Coal - 120000 TPA 120000 TPA Local Market

6 Strip RollingMill

Billet - 1,31,500 TPA 1,31,500 TPA In House

7 Re Rolling Mill Billet - 1,82,000 TPA 1,82,000 TPA In House

8 ERW PipeMfg. unit

Steel sheet - 1,30,000 TPA 1,30,000 TPA In House

9 Galvanisationunit

ERW Pipe - 30,000 TPA 30,000 TPA In House

10 Captive powerplant (AFBC)

Coal - 13,000 TPA 13,000 TPA Local Market

Dolochar - 1,10,000 TPA 1,10,000 TPA In House

Raw materials will be received at plant site by rail/road. All the trucks for raw material and

finished product transportation shall comply with the applicable environmental norms. The

Material-Cum-Process flow diagram for the proposed project has been depicted in

Figure-13 a & 13 b respectively.

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Figure-13 a : Indicative material balance-cum-process flow diagram for the proposedproject

Figure-13 b : Material balance-cum-process flow diagram for the proposed AFBCbased CPP

(vii) Resource optimization/ recycling and reuse envisaged in the project, if any, shouldbe briefly outlined.

The company has proposed several resource optimization/recycling and reuse measures

to make the proposed project more environmental friendly. Some of the measures are

briefly described below:

The heat from the DRI unit will be recovered in the form of hot gas and will be

used in the WHRB unit to generate electricity [8 MW (to be implemented for

which EC has already been granted) + proposed 18 MW=26 MW] which will meet

the partial electricity demand of the plant.

The gases passing out of WHRB & AFBC boilers will be passed through

Electrostatic Precipitator before escaping into the atmosphere. The dust content

in gas down stream of ESP shall be limited to 30 mg/Nm3. The dust particles (fly

ash) will be collected below ESP in hoppers and conveyed by means of

conveyors or pneumatically and stored in silos. This will be subsequently sold to

the cement and brick manufacturing industries.

Dolochar, which is a solid waste of the DRI unit will be used in the AFBC boiler in

combination with coal thereby reducing the coal consumption for this process.

Coal (13,000 TPA)

Dolochar (1,10,000 TPA)

6 MW CAPTIVE POWER PLANT

(AFBC based)

Fly ash (65,760TPA) will be soldto cement plants/brick

manufacturers

Bottom Ash (16,440 TPA) willbe used for land filling / road

construction purposeNote:

Assume, 40% ash in coal & 70% ashin Dolochar.

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The scraps from the rolling mill, ERW and GI pipe manufacturing units will be

used in the induction furnaces.

The Waste water generated from the different areas of the plant will be treated to

the desired extent in suitable treatment facilities and recycled back to the process,

as far as practicable, facilitating adequate reuse of-water in the respective

recirculating systems and economizing on the make-up water requirement.

Domestic waste water will be treated in STP. The water thus collected shall be

used for dust suppression at raw material handling system, landscaping etc. Thus,

Water system will be designed for “Zero Discharge” wherein all discharges will be

treated and reused in the plant.

Phenolic wastewater generated during the stage of gas cooling shall be charged

in the ABC of DRI plant and will also be used for making green ball for using it in

pellet kiln. Over flow water, spillage water will be connected to underground tank,

where the tar will be separated. Soft water plant will be installed so as to maintain

the pH. Plant will be designed for Zero discharge and spillage water will be used

for spraying on coal and coke if necessitated.

The proposed captive power plant will employ air cooled condenser which will

drastically bring down the water requirement.

(viii) Availability of water and its source, energy /power requirement and source shouldbe given.

a) Water Requirement and SourceDaily fresh water requirement for the existing plant is 514 m3/day and for the proposed

Project, it will be around 2,464 m3/day. Hence, the total water requirement of the overall

project will be 2,978 m3/d. The source of water is Table- 7.0 shows unit wise requirement

of water. Overall Water Balance Diagram is presented in Figure-14.0.

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Table - 7.0 : Unit wise Water Requirement Breakup

Sl.No.

Description Existing + To beimplemented(m3/day)

Proposed(m3/day)

1. Iron Ore Beneficiation Plant - 500

2. Pelletization Plant - 685

3. Producer Gas Plant - 120

4. DRI Unit 360 680

5. SMS with Caster 40 100

6. Strip Rolling Mill - 20

7. Re-Rolling Mill - 30

8. ERW pipe manufacturing unit - 5

9. Pipe galvanizing unit - 10

10. Captive Power Plant 96 270

11. Domestic demand 18 44

Total 514 2464

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Chhattisgarh.

Figure-14.0 : Indicative water balance diagram

360

Evp. Loss (84)

12

72

5

Note: All units are in m3/d

Source: Bore Well

10

1

395

34

Proposed (2,464 m3/d)

Iron Ore Beneficiation(1X2.67 MTPA)

Evp. Loss (400)

100

Pellet plant(2X0.8 MTPA)

Evp. Loss (685)685

DRI(2X350 T)

Evp. Loss (544)

136 680

SMS(3X20 T)

Evp. Loss (80)

20 100

Strip Rolling mill(0.13 MTPA)

Evp. Loss (16)

4 20

Re Rolling mill(0.18 MTPA)

Evp. Loss (24)

6 30

ERW(0.1 MTPA)

Evp. Loss (4)

Domestic 44

Galvanizing unit(0.03 MTPA)

Evp. Loss (8)

2

500

CPP (18 MWWHRB+6MW AFBC)

Evp. Loss (236)

270

92

390

Wastewater

Process dustsuppression, ashhandling, floorcleaning, greenbelt development

etc

Treatmentfacility

5

303

48

Existing/Not yet implemented (514m3/d)

Evp. Loss (288)

40

Evp. Loss (32)

CPP(8 MWWHRB) *

96

SMS(1X6 +1X8 +2X15 T)

8

DRI (4X100 TPD)

Domestic

STP

1518

*8 MW WHRB has not beenimplemented for which EChas already been granted.

PGP 3x60000 +2X8000120

24 Evp loss (96)

35

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Chhattisgarh.

b) Power Requirement and SourceThe estimated power requirement of the existing units is around 15 MW and that of the

proposed units is around 41 MW which will be sourced from the 32 MW capacity of

captive power plant & balance from the state grid. Unit wise power breakup for the

overall project has been presented in Table-8.0.

Table-8.0: Power requirement details for the overall projectSlNo

Description Existing/Notyet

implemented(MW)

Proposed(MW)

1. Pellet Plant - 6

2. Iron Ore Beneficiation Plant - 5

3. DRI Unit 1 2

4. SMS with Caster 13 18

5. Captive Power Plant 0.5 1.5

6. Strip & Re-Rolling Mill - 5

7. ERW pipe manufacturing unit - 2

8. Auxiliary & other loads 0.5 1.5

Total 15 41

(ix) Quantity of waste to be generated (liquid and solid) and scheme for theirmanagement/disposal

The pollutants in the form of solids, liquids and gases are expected to be generated from

various Units viz., Iron ore beneficiation and pelletization, Steel manufacturing and

Captive Power Plants. Release of such pollutants without proper care may affect the

environment adversely. Pollution of the environment not only adversely affects the

human beings, flora and fauna but also shortens the life of plant and equipment. This

vital aspect, therefore, has been taken into account while planning the plant and

equipment and adequate measures have been proposed to limit the emission of

pollutants within the stipulations of statutory norms.

Water Pollution Control

Process water to the tune of 395 m3/d generated from the overall project (existing

and the proposed units) will be treated to the desired extent in suitable treatment

facilities and recycled back to the process, as far as practicable, facilitating

adequate reuse of-water in the respective recirculating systems and economizing

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Chhattisgarh.

on the make-up water requirement. Domestic waste water to the tune of 62 m3/d

generated from the overall project will be treated in STP. The water thus collected

shall be used for dust suppression at raw material handling system, greenery

purposes, ash handling etc. Thus, Water system will be designed for “Zero Liquid

Discharge” wherein all discharges will be treated and reused in the plant.

The proposed captive power plant will employ air cooled condenser, which will


The Boiler blowdown will be controlled to maintain system solids loading within

normal limits for proper water chemistry. The effluent will have less than 100 ppm

suspended solids and will be led into the station sump mix with other station

effluents to reduce temperature and utilized for disposal of ash in slurry form.

Surface run-off will be settled in a settling basin prior to reuse/ disposal.

Treatment of waste water from Producer Gas Plant : Phenolic wastewater

generated during the stage of gas cooling shall be charged in the ABC of DRI

plant and will also be used for making green ball for using it in pellet kiln. Over

flow water, spillage water will be connected to underground tank, where the tar

will be settled. Soft water plant will be installed so as pH is maintained. Plant will

be designed for Zero discharge and spillage water will be used for spraying on

coal and coke if necessitated.

In Indirect Type Centrifugal Tar Separator, there is no direct contact of gas with

water. The cooling is done by heat transfer through wall to circulating water. Tar

is removed by centrifugal action without any washing with water. Therefore,

phenolic water is not generated in this method of tar separation and the

associated water pollution issues are completely eliminated.

Process water will be recycled in the system and over flow of the underground

tank will be reused /recycled for the water seals and secondary application in

gasifier plant. Occasional disposal of seal-water which would contain traces of

phenols would be incinerated in the after burning chambers of sponge iron kilns.

Treatment of waste water from Galvanizing Unit: The primary liquid waste is

spent pickling acid from the acid bath. The spent acid will be treated by

neutralization by using lime chips. After neutralization, iron oxide sludge will be

produced. After neutralization, the effluent will be stored in the sedimentation tank

after which the iron oxide sludge will pass through the filter press. The

supernatant liquid will be used for non-critical purposes like dust suppression etc.

inside the plant. The cake received from the filter press will be packed in polybags

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Chhattisgarh.

and will be stored at a secluded and secured place inside the plant area for its

disposal through registered vendors. Hence, an Effluent Treatment Plant (ETP)

will be installed with the Galvanizing Unit.

Solid Waste Management

Solid wastes that will be generated from IFs are slag and dust. The hot slag

generated from IF will be transferred to slag yard after cooling. IF slag will be

used for road construction and land filling purposes after metal recovery in the

metal recovery plant.

Dolo-char from the DRI unit will be used in AFBC boiler.

Solid wastes that will be generated from SMS with continuous caster units are the

scales. The scales are collected from the drain and transferred to IF for reuse.

The solid wastes from the rolling mill are end cuts and miss rolls, which will be re-

used in induction furnace.

The fly ash generated from Captive Power Plant will be sold as a raw material for

cement plants and brick manufacturing. The bottom ash from CPP will be used as

land filling.

Tailing from I/O Beneficiation plant will be used for Brick manufacturing / Paver

block making / aggregate in concrete / road construction purpose. No tailing pond

has been proposed inside the plant premises.

Generated Tar from the proposed producer gas plant will be temporarily stored at

an isolated location inside the plant premises. Finally, it will be sold to authorized

re-processors

Solid & Hazardous waste generation and its disposal for the overall project are presented

in Table-9.0.

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Chhattisgarh.

Table-9.0: Solid & Hazardous waste generation and its disposal from the overall project

Sl.No.

Type Existingproject(TPA)

Proposedproject(TPA)

Total(TPA)

Utilization

1. Tailings from I/OBeneficiation Plant

- 10,70,000 10,70,000 To be used for Brick manufacturing/ Paver block making / aggregate inconcrete / road constructionpurpose.

2. Dolo Char from DRIPlant

40,000 70,000 1,10,000 To be used in AFBC Boiler for powergeneration.

3. Slag & dust from SMS(IFs)

14,900 20,317 35,217 To be used for Land filling / RoadConstruction purpose / paver blockmaking after metal recovery.

4. Scale, end cuts etc.from SMS

6,497 4,765 11,262 To be used in Induction Furnaces.

5. Scale, end cuts etc.from SRM & RRM

- 3,500 3,500 To be used in Induction Furnaces.

6. Zinc Dross fromGalvanising unit

- 200 200 To be sold to the AuthorisedVenders

7. Fly Ash from AFBCBoiler

- 65,760 65,760 To be used as a raw material forcement and brick manufacturing.

8. Bottom Ash fromAFBC Boiler

- 16,440 16,440 To be used for land filling / roadconstruction purpose.

9. Tar sludge from PGP - 5,389 5,389 To be sold to the AuthorisedVenders

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Chhattisgarh.

(x) Schematic Representations of the feasibility drawing which give information of EIAPurpose

Figure 15.0 presents the steps involved in environmental clearance process.

Figure-15.0: Schematic representation of processing for prior environment clearance

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Chhattisgarh.

4.0 SITE ANALYSIS

(i) ConnectivityThe project site already has proper road linkage for transport of materials and equipment.

The nearest Railway Station is Bhupdeopur Railway Station, which is located about 14.2

km distance (aerially) at south-west direction from the project site. The distance of

Raigarh Railway station from the project site is about 20.5 km (aerially), located at ‘SSE’

direction w.r.t. the project site. NH-200 (Raipur, Bilaspur, Sarangarh, Raigarh, Deogarh,

Talcher and Chandikhol linking National Highway) is passing through Raigarh about 19

kms distance (aerial distance) at south direction from the project site. The nearest Airport

is Raipur Airport in Chhattisgarh i.e., known as Swami Vivekanand International Airport,

which is located at about 250 km (aerial distance) in west direction from the project site.

NH-200 connects the project site with the airport at Raigarh. The project site has good

connectivity with port of Vishakhapatnam.

(ii) Land form, Land use and Land ownershipThe proposed project will be located at Village: Punjipatra, Tehsil Tamnar, District

Raigarh in Chhattisgarh. The proposed units will be installed on the available land within

the existing plant premises of 23.4718 ha (58 acre) as well as on some additional land

[12.34291 ha (30.5 acre)], adjacent to the existing plant premises, thus comprising a total

land area of 35.81468 hectare (88.5 acres) at Village: Punjipatra, Tehsil Tamnar, District

Raigarh in Chhattisgarh. The additional land is vacant and industrial in nature. The

acquisition of this additional land is under process. The additional land is vacant and

industrial in nature.

The important river in the study area is Kelo River, which flows at a distance of 6.3 kms

at ESE direction from the project site. This river is a main tributary of River Mahanadi

which is the major important river in Chhattisgarh. Kurket River which is another

important river in the study area is flowing about 7.6 kms away at WNW direction from

the project site. The Rabo dam which is situated on the way of the Kurket River is

located about 7 kms distance at west direction from the project site. The project site is

around 73 m above Kurkut River bed and Robo dam and thus there is very less chance

of occurrence of flood in the project site. As per existing land used pattern, land is

generally flat and no major earth filling is required for the implementation of the proposed

project.

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Chhattisgarh.

(iii) TopographyRaigarh District covers an area of 6275 sq. km., between latitudes 21º20'N to 22º46'N

and longitudes 82º55'E to 83º50'E and is divided into six (6) tehsils and nine (9) blocks.

The study area has a slightly rugged topography with ridges and isolated hills of

Cuddapah sandstones, running in a more or less N.W. – S.E. direction. The southern

portion of Tamnar tehsil which is in the study area is slightly hilly. The low hills here are

made up of Kamthi Sandstones, and these are covered with fairly dense jungle. The

plains south of Raigarh, imperceptibly sloping to the south, forms a part of the Mahanadi

valley, and consist of rich paddy fields. The flat country around Tamnar and Tamnar is

formed of low dipping Barakar sandstones. Eco-sensitive areas like National Park and

Wildlife Sanctuary is not found in the study area, but there are several Reserve Forests

viz. Urdhana RF, Taraimal RF, Kharidungari RF, Maghat RF, Pajhar RF, Rabo RF,

Lakha RF, Barakachar RF, Dungapani RF, Punjipatra RF, Suhai RF, and Samaruma RF

are existed within 10 km radius study area around the Project site.Topographically the

plant site area is generally flat without major undulations. The plant area may not require

significant grading and leveling work for the structures and buildings. Elevation of the

overall project site is varying in the ranges between 300 m to 305 m above Mean Sea

Level.

The topographic map indicating the project site is given Figure-16.0 below:

Figure-16.0: Topographic Map indicating the project site

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Chhattisgarh.

(iii) Existing land use pattern (agriculture, non-agriculture, forest, water bodies (includingarea under CRZ), shortest distances from the periphery of the project to periphery of theforests, national park, wild life sanctuary, eco sensitive areas, water bodies (distance fromthe HFL of the river), CRZ. In case of notified industrial area, a copy of the Gazettenotification should be given

The existing environmental settings of the area has been presented in Table 10.0 below:

Table - 10.0: Environmental Settings of the Area

S.NO.

PARTICULARS

DETAILS

(with approximate aerial distance & direction from the nearest plant

boundary)

1. Existing landuse The proposed project will be located at Village: Punjipatra,

Tehsil Tamnar, District Raigarh in Chhattisgarh.

The proposed project will be installed on the available land

within the existing plant premises of 23.4718 ha (58 acre) as

well as on some additional land [12.34291 ha (30.5 acre)],

adjacent to the existing plant premises, thus comprising a total

land area of 35.81468 hectare (88.5 acres) at Village:

Punjipatra, Tehsil Tamnar, District Raigarh in Chhattisgarh. The

additional land is vacant and industrial in nature. The

acquisition of this additional land is under process.

The 10 km radius study area of the proposed project site is

largely surrounded by arable mono cropped land followed by

forest land. Patches of vacant waste land, rural settlements

along with industrial area are also present within the 10 km

radius of the project site.

2. National Parks, Wildlife

Sanctuaries, Biosphere

Reserves, within 10 km

radius

There is no National Park, Wildlife Sanctuary, Biosphere

Reserve located within 10 Km radius study area.

3. Reserved Forests (RF) /

Protected Forests (PF) within

10 km radius

Eco-sensitive areas like National Park and Wildlife Sanctuary is

not found in the study area, but there are several Reserve

Forests viz. Urdhana RF, Taraimal RF, Kharidungari RF,

Maghat RF, Pajhar RF, Rabo RF, Lakha RF, Barakachar RF,

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Chhattisgarh.

S.NO.

PARTICULARS

DETAILS

(with approximate aerial distance & direction from the nearest plant

boundary)

Dungapani RF, Punjipatra RF, Suhai RF, and Samaruma RF

are existed within 10 km radius study area around the Project

site. There is an important Deep forest Jungle named

‘Samaruma Jungle’ which is situated at a nearest distance of

about 2 kms at north direction from the Project site.

4. Water Bodies (within 10 kmradius)

The important river in the study area is Kelo River which flows

at a distance of 6.3 kms at ESE direction from the project site.

This river is a main tributary of River Mahanadi which is the

major important river in Chhattisgarh. Kurket River which is

another important river in the study area is flowing about 7.6

kms away at WNW direction from the project site. The Rabo

dam which is situated on the way of the Kurket River is located

about 7 kms distance at west direction from the project site.

(v) Existing InfrastructureMost of the facilities are available for setting up of the proposed project such as

Electricity, Water, Transportation of raw materials and finished goods etc. Skilled and

unskilled workers are also easily available within the area.

Same will be extended in the proposed expansion also. For establishment and

successful operation of plant, it is imperative to ensure availability of the following

infrastructure:

Availability of raw coal & iron ore and its proximity to the plant to reduce cost oftransportation.

Road / Rail head connection so that the raw materials and products can be easilyand economically transported.

Availability of water.

Permanent and reliable source of power.

Adequate land for the plant, storage of raw material and products & disposal ofwaste material.

(vi) Soil classificationThe soils of Chhattisgarh vary considerably in the three agro-climatic zones. Though the

nomenclature is different, the types of the soils especially the physical properties are the

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Chhattisgarh.

same. The different soils that exist in the three agroclimatic zones are presented in

Table-11.0.

Table-11.0: Soil classification of Chhattisgarh

Agroclimaticzone

Districts Soil Characteristics

Chhattisgarh

Plains

Raipur, Gariyabandh, Baloda Bazar,

Mahasamund, Dhamtari, Durg, Bemetra,

Balood, Rajnandgaon, Kabirdham, Bilaspur,

Mungeli, Korba, Janjgir and part of Kanker

district (Narharpur & Kanker block) along with

part of Raigarh district

Bhata (Lateritic)

Matasi (Sandy

loam)

Dorsa (Clay loam)

Kanhar (Clay)

Bastar

Plateau

Jagdalpur, Kondagaon, Dantewada, Bijapur,

Narayanpur and remaining part of Kanker

district.

Marhan (Coarse

sandy)

Tikra (Sandy)

Mal (Sandy loam)

Gabhar (Clay &

Clay loam)

Northern hills Surguja, Surajpur, Balrampur, Koriya and

Jashpurnagar and Dharamjaigarh Tehsil of

Raigarh district.

Hilly soils

Tikra

Goda chawar

Bahara

The soils of Raigarh district have a large variation. The red coloured residual soil are

derived from the lateritisation of shale and sandstones and the areas covered by such

type of soil is known as “Bhata”. The black coloured soils are locally known as “Kanhar”

similarly there are pale yellow sandy loamy soils which are locally known as “Matasi” and

“Dorsa‟.

Ground water profile of the project site and surroundingsThe comprehensive ground water monitoring study has been undertaken by M/S ScaniaSteels & Powers Limited in the year 2020 as a compliance of the terms and conditions

imposed by Central Ground Water Authority (CGWA) while awarding the NOC for

withdrawal of ground water for the project.

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Chhattisgarh.

The broad objective of the study was to assess the impact of ground water abstraction

on ground water storage and its quality and to identify the potential areas that have

registered change in ground water levels and quality so as to plan appropriate measures.

An area of about 314 Sq. Km has been considered encompassing 10 km of radius

around the project site to study the impact of ground water withdrawal. The study was

conducted to understand the overall picture of ground water regime changes and storage

behavior due to continuous abstraction of ground water in the project area has been

analyzed for the period January 2010 to Nov 2020.

The analysis of data in general indicates that there is insignificant impact of ground water

withdrawal from the project area on the overall ground water regime of the area. The

depth to water level of May / June 2020, in area remains between 2.3 to 20.75 meters

below ground level in core and buffer zone. The pre-monsoon depth to water indicates

that water levels between 5 to 10 mbgl are observed in the Samaruma, Punjipathara and

Amlidih villages of core zone and 43% of villages of buffer zone. Water levels between

less than 5 mbgl are observed in the Tumidih, Jhingalpara villages of core zone and 57%

of villages of buffer zone. Deeper water levels of more than 10 mbgl are observed in the

all PZ within the core zone and at Tamnar villages of buffer zone. As such the deeper

water level of more than 10 mbgl has been observed in and around the project area and

also fall on the water divide.

The depth to water level of November 2020 in area remains between 2 to 21.4 meters

below ground level in core and buffer zone. The spatial distribution of post-monsoon

depth to water broadly follows similar pattern as of pre-monsoon water level. Water

levels between 3 to 5 mbgl are observed In the villages of core zone namely Samaruma,

Punjipathara and Amlidih and 71% of villages of buffer zone.

Water levels between less than 3 mbgl are observed in the Tumidih village of core zone

and 14 % of villages of buffer zone. Deeper water levels of more than 5 mbgl are

observed in the all PZ and Samaruma within the core zone and at Deogaon, Suhai &

Tamnar villages of buffer zone . As such the deeper water level of more than 5 mbgl has

been observed in and around the project area and also fall on the water divide. Water

level fluctuation in the study area varies from 0.0 to 5.0 meters. Lower range of water

level fluctuation is also observed along the river course followed by 1 to 2, 2 to 3,3 to 4

and > 4 m.

Overall, from the comparison of mean water levels of the year 2010 to 2019 with respect

to the years 2020, in pre-monsoon period, it is found that all the villages in core zone,

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Chhattisgarh.

which are considered for analysis showing rising in the range of 0.2 to 5.61 m. and all of

the villages in buffer zone are showing rise in range of 1.17 to 6.15 m. In post-monsoon

period, it is found that all the villages in core zone, which are considered for analysis are

showing rise in the range of 0.46 to 3.51 m. except Jhingalpara, PZ1 and PZ2 village

which is showing decline in water level-0.16 to -0.65 m, 38% of the villages in buffer

zone are showing rise in range of 0.04 to 2.35 m while 62% villages are showing decline

in water level in the range of -0.04 to -1.74 m. The area showing falling trend more than

20 cm/yr are of considerable significance, which is attributed to increase in draft in

selective patches.

In conclusion, if the decline per year is more than 0.20 m then for the period of eleven

years it will be more than 2.2 m which is considered as significant but in the present

scenario all the villages of core zone and buffer zone considered for analysis shows

decline less than 2.2 m over the period of eleven years, so it is evident that there is a

marginal decline in water level trend in post-monsoon period over the period of eleven

years.

The analysis of the chemical data shows that, the quality of ground water in the area

(both core and buffer zone) is generally alkaline in nature. All major ions are within the

limits of Bureau of Indian Standards for drinking purposes and meet the quality

requirements of irrigation. Thus, ground water is suitable for irrigation, domestic as well

as drinking purposes and there is no remarkable change in chemical quality of ground

water in and around the area.

(vii) Climatic data from secondary sourcesThe meteorological data described in this section have been collected from the IMD

Station located at Raigarh, which deemed to be representative of the study area.

The climate of the project area is humid and tropical. It is characterised by a hot and dry

summer from March to May, a south-west monsoon or rainy season from June to

September, a pleasant post-monsoon or retreating monsoon from October to November

and a cool winter from December to February. Therefore, climatologically, four seasons

viz. summer (pre-monsoon), monsoon, post-monsoon and winter could be deciphered

comprising the following months:

Summer : March, April, May

Monsoon : June, July, August, and September

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Chhattisgarh.

Post-monsoon : October, November

Winter : December, January, and February

Available meteorological data for the past 30 years’ period (1971-2000) have been

collected and have been summarized. The climatic features of this station are presented

in Tables-12 a & 12 b.

TemperatureThe pre-monsoon mean daily maximum temperature is observed to be 42.2°C (May)

with the mean daily minimum temperature as 16.8°C (March). An appreciable drop in

mean daily maximum temperature is recorded with the onset of monsoon. The monsoon

remains between June to September. The mean daily maximum temperatures during

monsoon season is recorded as 32.5°C in the month of July and mean daily minimum

temperature is observed in the month of September as 22.4⁰C. By the end of September

with the onset of post monsoon season (October-November), day temperatures drop

slightly with the mean daily maximum and minimum temperatures of 33.9°C and 13.2°C

in the month of October and November respectively. The winter season starts from the

December and continues till the end of February. During this season, mean daily

maximum temperature is observed as 28.7°C in the month of February and the mean

daily minimum temperature of 9.2°C is observed in the month of January. The monthly

variations of temperatures are presented in Table-12 a.

Relative HumidityIn the pre-monsoon period (March-June) the mean maximum relative humidity is

observed to be 63% in the month of June. The mean minimum humidity is observed in

the month of April as 35%. During the monsoon season the mean maximum humidity

observed is 87% (August), while the mean minimum humidity is observed to be 64% in

the month of September. In post monsoon season, the mean maximum humidity value is

recorded as 64% in the month of October. The mean minimum value is recorded as 36%

in the month of November. During winter season, the mean maximum humidity is found

to be 67% in month of January, whereas the mean minimum value is recorded at 29% in

the month of February. The monthly mean variations in relative humidity are presented in

Table-12 a.

Rainfall and Rainy DaysThe total annual mean rainfall received is about 839.4 mm at Raipur (Table-12 a).Rainfall was peaked during the month of August (mean monthly rainfall in July was 312.3

73 | P a g e



Chhattisgarh.

mm). The lowest rainfall occurred during the month of December (mean monthly rainfall

in February was 1.5 mm). Total annual mean number of rainy days was about 39.5 in

Raipur.

Cloud CoverThe mean monthly data revealed that the cloud cover in day time ranged between 1.1

Oktas (at month of february) to 6.9 Oktas (at month of August) and in night time it ranged

between 1.5 Oktas (at month of November) to 6.9 Oktas (at month of August). The

overall annual mean cloud cover was found 2.5 Oktas and 3.2 Oktas in day and night

time respectively (Table-12 a).

Wind Speed and DirectionThe predominant wind speed is found to be observed between 1-19 km/h during the

months of July and August in SW direction (Table-12 b).

Table-12 a : Mean Monthly Summary of Climatological Data Collected from IMD, Raigarh(1971-2000)

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Chhattisgarh.

Table-12 b: Mean Monthly Summary of Climatological Data Collected from IMD, Raipur(1971-2000)

(viii) Social Infrastructure availableThe project site is well connected to all major cities by rail/road. There are no public

buildings, places and monuments in and around the vicinity of the plant area. Post

Offices, Bank facilities, Hospitals, temples etc are available around the project site. In

some of the villages Primary, Middle and Secondary School facilities are available for

education.

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Chhattisgarh.

5.0 PLANNING BRIEF

(i) Planning Concept (type of industries, facilities, transportation etc.) Town andcountry Planning/ Development authority classification.Facilities required for the proposed project shall be provided as per requirement.

Transportation of raw material and final product will be done via existing road network.

Details of the road network inside the plant for movement of vehicles, materials,

auxiliaries and human resources have been provided in detailed plant layout.

(ii) Population Projection

Raigarh city is already a developed city and has well-developed infrastructure. As per

provisional reports of Census India, population of Raigarh in 2011 is 137,126; of which

male and female are 70,197 and 66,929 respectively. Although Raigarh city has

population of 137,126; its urban / metropolitan population is 150,019 of which 76,865 are

males and 73,154 are females

Most of the employment will be generated from the local areas only. The required

manpower for the proposed Plant can be classified into grades such as Executive,

Senior & Junior Managerial, Supervisory, High Skilled, Skilled, Semiskilled, Unskilled and

Staff. Such grading facilitates fixing of total emoluments in a few broad categories.

The Demographic and Socio economic characteristics with regards to demography,

literacy and occupational status will be describe in EIA report.

(iii) Land use planningThe proposed units will be installed on the available land within the existing plant

premises of 23.4718 ha (58 acre) as well as on some additional land [12.34291 ha (30.5

acre)], adjacent to the existing plant premises, thus comprising a total land area of

35.81468 hectare (88.5 acres) at Village: Punjipatra, Tehsil Tamnar, District Raigarh in

Chhattisgarh. The additional land is vacant and industrial in nature. The acquisition of

this additional land is under process.

In developing the plant general layout, expeditious movement of processing materials

must be considered. The factors, which have been taken into consideration, are

indicated below:

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Chhattisgarh.

i. Economical & uninterrupted receipt of incoming raw materials & supplies; inter-

departmental dispatch of in process materials upto finishing stage and disposal of

plant wastes with minimum counter flow of materials particularly inside the shops.

ii. Logical locational arrangement of production units, plant services and ancillary

facilities to ensure minimum capital and operating costs both during the initial stage

and future expansion.

iii. Compactness of plant layout minimizing the distance of internal communications

and inter plant handling of processing materials without sacrificing operational

efficiency.

Table-13.0 shows the break-up of the land use of the project site/area:

Table -13.0: Land use break-up

(iv) Assessment of infrastructure demand (Physical & Social)

Raigarh city is a developed area with all sorts of infrastructure required to install any new

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factory/plant. In the instant scenario, M/s Scania Steels and Powers Limited will have

no problem to supply the finished products in the nearby areas. To add further availability

of power, water and human resource (skilled and unskilled) will not pose any problem at

Raigarh. It may be prudent to mention that the project site is well connected by both rail

and surface transport with rest of India.

(v) Amenities/Facilities

To render necessary repair & maintenance, inventory, quality control related and

administrative services for the proposed project, following auxiliary facilities have already

been been provided inside the existing plant boundary which have been listed below:.

Repair and maintenance shop Stores Plant office Ancillary buildings

6.0 PROPOSED INFRASTRUCTURE

(i) Industrial Area (Processing Area)

For setting up of the Main Plant Facilities, Raw Material Storage, Water Storage

Reservoir, Auxiliary facilities, viz. Admn. Bldg., Tech. Bldg, Workshop, QC Lab, Switch

Yard, etc., 88.5 Acres of land shall be required. The company will use nearest road and

rail facility for goods transportation.

(ii) Residential area (Non-Processing area)The area around the site is under development with limited facilities.

Around 691 people will be engaged in the plant during operational stage of the proposed

project and nearby Raigarh city is close to the project site. Hence, no residential

colony/township is envisaged for employees.

(iii) Green Belt

In the existing plant area, there is significant presence of the greenbelt. Out of the total

plant area of 23.472 hectares (58 acres), the area covered under plantation is 7.85

hectares (19.4 acres). Hence, over 33% of the total plant area is covered under

plantation. Around 19500 plants/ trees are existing in the plant area.

The proposed project will be installed on the available land within the existing plant

premises of 23.4718 ha (58 acre) as well as on some additional land 12.34291 ha (30.5

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acre), adjacent to the existing plant premises, thus comprising a total land area of

35.8168 hectare (88.5 acres). 33% of total of land will be developed as greenbelt.

Green belt development will further act as a traffic noise barrier. Green belt helps to

check soil erosion, makes the ecosystem more friendly and functionally more stable,

make the climate more conducive and restore water balance. Tree species shall be

selected considering tolerance to specific conditions or alternatively wide adaptability to

eco-physiological conditions. The tree species selected for green belt shall include the

native species like Butea Monosperma, Dalbergia Sissoo , Cassea Fistula,

Azadirachta Indica etc.

(iv) Social InfrastructureThe existing infrastructure facilities such as transportation, road networks, water

resource etc. are adequate at the project site. The social infrastructures like school,

college, temples and hospitals already exist in and around of this area. The above

infrastructure facilities need no further development for the project nor is any major

change in the infrastructure envisaged due to the project. Direct and indirect employment

generation is envisaged from the proposed project. Some glimpses of the developmental

activities are presented below:

Improving and building road network in the adjoining villages.

Strengthening School buildings with playgrounds.

Social awareness programme to improve the sanitation and hygiene, of the local

people.

The Proposed Project will set up training centre or tie up with Industrial Technical

Institutes to educate local youth as skilled labour.

(v) Connectivity (traffic and transportation road/rail/metro/water ways etc.)

The Site is well connected to Raigarh – Ambikapur Highway and same will be used for

transportation of Raw material, Product and Solid waste. Major raw material like Coal,

Iron ore etc. will be transported upto Raigarh Railway Station and from their by road (i.e.,

through Raigarh – Ambikapur Highway ) upto the plant.

(vi) Drinking Water Management

Existing domestic water requirement is 18 KLD and additional 44 KLD will be required for

the proposed expansion project. Thus, total domestic water requirement after proposed

expansion will be 62 KLD and the same will be sourced from bore well.

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(vii) Sewerage System

Domestic waste water (50 m3/d) generated from office toilets, & canteen will be treated in

STP.

(viii) Industrial Waste management

For Air Environment

Plantation and Green belt development (33% of the plant area) have been taken

up all along the roads, plant premises etc.

Roads are/will be frequently sprinkled with water.

Adequate control measures like installation of Electrostatic Precipitator (ESP),

bag filters, dust suppression system, Dry Fog system and stacks of adequate

height at relevant points.

All the major stacks are/will be equipped with online continuous monitoring

system to ensure the desired efficiency of the respective control systems.

Most of the raw materials are being/will be stored under covered shed.

Regular maintenance of vehicles and machinery are being / will be carried out in

order to control emissions.

All bulk material carrying trucks are being/will be well covered with tarpaulin.

Facility for washing dust from wheels of incoming and outgoing trucks for the

proposed project through an water bath is/will be set up at the entrance of the

gate.

Transportation of materials is being / will be limited to day hours only.

For water environment

Waste water generated from the different areas of the plant will be treated to the

desired extent in suitable treatment facilities and recycled back to the process, as

far as practicable, facilitating adequate reuse of-water in the respective

recirculating systems and economizing on the make-up water requirement.

Domestic waste water will be treated in Sewage Treatment Plant. The water thus

collected shall be used for dust suppression at raw material handling system,

landscaping etc. Thus, Water system will be designed for “Zero Discharge”

wherein all discharges will be treated and reused in the plant.

The proposed captive power plant will employ air cooled condenser which will


The Boiler blowdown will be controlled to maintain system solids loading within

normal limits for proper water chemistry. The effluent will have less than 100 ppm

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suspended solids and will be led into the station sump mix with other station

effluents to reduce temperature and utilized for disposal of ash in slurry form.

Surface run-off will be settled in a settling basin prior to reuse/ disposal.

Treatment of waste water from Galvanizing Unit: The primary liquid waste is spent pickling

acid from the acid bath. The spent acid will be treated by neutralization by using lime chips.

After neutralization, iron oxide sludge will be produced. After neutralization, the effluent will be

stored in the sedimentation tank after which the iron oxide sludge will pass through the filter

press. The supernatant liquid will be used for non-critical purposes like dust suppression etc.

inside the plant. The cake received from the filter press will be packed in polybags and will be

stored at a secluded and secured place inside the plant area for its disposal through registered

vendors.

(ix) Solid Waste Management

Solid wastes that will be generated from IF are slag and dust. The hot slag

generated from IF will be transferred to slag yard after cooling. IF slag will be

used for road construction and land filling purposes after metal recovery in the

metal recovery plant.

Dolo-char from the DRI unit will be used in AFBC boiler.

Solid wastes that will be generated from SMS with continuous caster units are the

scales. The scales are collected from the drain and transferred to IF for reuse.

The solid wastes from the rolling mill are end cuts and miss rolls, which will be re

used in induction furnace.

The fly ash generated from Captive Power Plant will be sold as a raw material for

cement plants and brick manufacturing. The bottom ash from CPP will be used as

land filling.

Tailing from I/O Beneficiation plant will be used for Brick manufacturing / Paver

block making, aggregate in concrete, road construction purpose. No tailing pond

has been proposed inside the plant premises.

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

As such there is no requirement of R&R plan since no evacuation / ejection of habitation

will take place. The entire project area is industrial in nature and there is no habitation.

So there will not be displacement of any person.

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8.0 PROJECT SCHEDULE AND COST ESTIMATES

(i) Likely date of start of construction and likely date of completionThe installation of several production units along with utilities and services will involve

award of all contracts, procurement of plant and equipment, construction & erection and

supervision of all activities at plant site.

The factors which are responsible for timely implementation of the project are:

Arrangement of proper finance for the project.

Finalization of layout of the proposed plant.

Design of utilities and services.

Placement of orders for plant and machinery.

Arrangements for Govt. sanctions and supply of power.

Recruitment of personnel.

As per an initial estimate, around 36 months will be needed for implementation of the

proposed project.

(ii) Estimated project cost along with analysis in term of economic viability of the projectThe Total cost of the Project will be around Rs. 629 Crores. The details of cost are given

below in Table 15.0 below :

Table-15.0: Cost breakup of the proposed project

SlNo.

Particulars Total Value inCrores

1 Pelletization Plant 180

2 Coal gasifier and Pulverizer Unit 6

3 Iron Ore Beneficiation Plant 60

4 DRI Unit 75

5 SMS with Caster 50

6 Captive Power Plant 168

7 Strip Rolling Mill 50

8 ERW pipe manufacturing unit 25

9 Pipe galvanizing unit 05

10 Admin Office, Store, Land

Security & Street Light, Boundary Wall,

Heavy Vehicles

20

11 Green Belt 2

Total 641

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9.0 ANALYSIS OF PROPOSAL

(i) Financial and social benefits with special emphasis on the benefit to the localpeople including tribal population, if any, in the areaThe focus of proposed project is cost reduction by producing quality material as per the

required specification. There will be complete integration right from the beginning to

finished products. The estimated cost of the project is expected to be around Rs. 641

Crores. There will be substantial savings due to the said project as company will also be

eligible for various incentives. The total project is expected to be commissioned over a

period of 36 months in phased manner. The benefit from the projects planned will start

accruing from year one only. Besides, there will be immense social benefits of the

project, to the backward region.

Improvements in the Physical Infrastructure

The plant will result in considerable growth of service sector & infrastructure

development.

Supporting infrastructures as roads, rail power supply etc. already exist at the site.

Improvements in the Social Infrastructure

No environmental significant impacts are envisaged due to ancillary developments.

Mitigative measures will be proposed for management of anticipated impacts;

Community development activities will be initiated under CER programs;

Revenue to the exchequer in the form of power tariff and taxes etc; and

Opportunity for industrial development in the state.

Employment

It is estimated that the total requirement of manpower during operational phase will be

691. There will be much larger indirect employment in transport, ancillary, support

facilities and growth in local trades and business.

PROJECT FEASIBILITY REPORT - Environmental Clearance

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